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Lexmark J110

4085-001

• Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4085-001
Edition: August 2001 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark, Lexmark with diamond design, MarkNet, and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. OptraImage and PerfectFinish are trademarks of Lexmark International, Inc. Other trademarks are the property of their respective owners. © Copyright Lexmark International, Inc. 2001. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

U.S.A. P/N: 12G3639

4085-001

Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Internal Power Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Operator Panel and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Using the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Power Indicator States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Operator Panel Button Functions. . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Operator Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Printing the Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Disabling the Operator Panel Menus . . . . . . . . . . . . . . . . . . . . . 1-10 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Error Indicator Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Attendance Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Overriding Change Prompts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . 2-49 Post Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Maintenance Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Maintenance Station Service Checks . . . . . . . . . . . . . . . . . . . . 2-56

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4085-00X Index Motor Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 Sensor Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 Multi-Purpose Feeder (MPF) Motor and Sensor Service Check .2-58 Operator Panel (Buttons) Service Check . . . . . . . . . . . . . . . . . .2-59 Operator Panel (LCD) Display Service Check . . . . . . . . . . . . . .2-60 Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 Power Supply Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64 RIP Card Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Print Quality Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 Index Card/Sensor Service Check . . . . . . . . . . . . . . . . . . . . . . .2-68 Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68 Cam System Motor/Sensor Service Check . . . . . . . . . . . . . . . . .2-70 User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Printer Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Operations Initiated by Pressing Buttons at Power-On Reset. . . .3-1 Change Ink Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Change Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Aligning the Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Cleaning Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Linking Input Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Unsolicited Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Manual Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Restoring Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Canceling a Print Job using the Operator Panel . . . . . . . . . . . . .3-12 Resetting the Printer using the Operator Panel. . . . . . . . . . . . . .3-14 Other Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Activating Hex Trace Debug Mode . . . . . . . . . . . . . . . . . . . . . . .3-19 Diagnostics (Mode 1) - Print Tests . . . . . . . . . . . . . . . . . . . . . . .3-19 Diagnostics (Mode 2) - Hardware Tests . . . . . . . . . . . . . . . . . . .3-22 Diagnostics (Mode 2) - Input Tray Tests . . . . . . . . . . . . . . . . . . .3-27 Diagnostics (Mode 2) - Base Sensor Tests . . . . . . . . . . . . . . . . .3-29 Diagnostics (Mode 2) - Subsystem Tests . . . . . . . . . . . . . . . . . .3-31 Diagnostics (Mode 2) - Supplies Tests . . . . . . . . . . . . . . . . . . . .3-34 Diagnostics (Mode 2) - Printer Setup . . . . . . . . . . . . . . . . . . . . .3-35 Diagnostics (Mode 2) - Error Log . . . . . . . . . . . . . . . . . . . . . . . .3-37 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 Understanding the Menu Display and Menu Buttons . . . . . . . . .3-39 Example of Modifying Printer Setting Using the Operator Panel.3-42 Operator Panel Menu Definition . . . . . . . . . . . . . . . . . . . . . . . . .3-44

iv Service Manual

4085-001 Busy/Waiting Menu Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Job Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ready Menu Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration Menu Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics Menu Group (Mode 1: Printing) . . . . . . . . . . . . . . . Diagnostics Menu Group (Mode 2: Non-printing). . . . . . . . . . . . 3-45 3-46 3-48 3-60 3-62 3-63

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operator Panel Cover/Operator Panel Removal . . . . . . . . . . . . . 4-5 Exit Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Left Frame Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Left Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Right Cover/Power Switch Removal . . . . . . . . . . . . . . . . . . . . . . 4-9 Left Tray Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Right Tray Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Ink Levels and Temperature Sensor with Bracket Removal . . . 4-13 Engine Board /Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Carrier with Card Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Carrier 1st Stage Drive Belt Removal . . . . . . . . . . . . . . . . . . . . 4-17 Carrier Printhead Latch Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-17 Multi-Purpose Feeder (MPF) Motor and Sensor Removal. . . . . 4-17 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Index Card Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Cover-Open Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 RIP-EMC Shield Assembly/RIP Card Removal . . . . . . . . . . . . . 4-24 PerfectFinish Sensor Assembly/Rear Paper Path Sensor . . . . 4-26 Frame From Base Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Cam Engine Motor with Gear Removal . . . . . . . . . . . . . . . . . . . 4-29 Paper Feed Pick Arm Assembly with Motor and Paper Path Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 PerfectFinish Gear Plate Removal. . . . . . . . . . . . . . . . . . . . . . . 4-32 PerfectFinish Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Index Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Encoder Disk Feed Roller Assembly Removal . . . . . . . . . . . . . 4-34 Star Wheel Shaft Assembly Removal . . . . . . . . . . . . . . . . . . . . 4-36 Paper Feed Platen Assembly Removal . . . . . . . . . . . . . . . . . . . 4-38

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. . . . . . . . . . . . . . . . . . .6-1 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . .4-45 Bat Wings and Bushings Removal . . . . . . . . . . . . . . . . . .5-4 Preventive Maintenance . . . . . . . . . . . . . . . . . . .5-3 Optional Tray 2 . . . . . .4-40 Left Index Frame Pivot Assembly Removal . . . . . . . . . . . . . . . . . . . . . . .4-39 Paper Feed Frame and Motor/Cam Shaft Assembly Removal . . . . .7-1 How To Use The Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 Peristaltic Pump Removal . . . . . . . . . . . . . . .4-50 Tray 2 Paper Feed Motor and Card Assembly Removal. . . . . . . . . . . . . . .7-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4085-00X Exit Shaft with Gear Removal . . . . . . . . . . X-1 vi Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 RIP Card . . . . . . . . . . . . . . . . . . . . . . . . .4-48 Carrier/Cable Retainer Removal . . . . . . . . . . . . . . . . . . . . . .4-46 Backup Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 RIP Card (cont. . . . . . . . .4-49 Tray 2 Covers Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 Right Index Frame Pivot Assembly Removal . . . .4-49 Tray 2 Paper Pick Arm Assembly Removal . . . . . . .6-1 Lubrication Specifications .4-47 Backup Roller Spring Removal . . . . . . . .

symptom tables. 2. 6. Parts Catalog contains illustrations and part numbers for individual FRUs. and service checks used to isolate failing field replaceable units (FRUs). as well as general environmental and safety instructions. 5. Diagnostic Information contains an error indicator table. Special tools and test equipment are listed in this chapter. Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems. 3. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. Connector Locations uses illustrations to identify the connector locations and test points on the printer. It is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Preface vii . 4.4085-001 Preface This manual describes the Lexmark J110 printer (4085-001) and contains maintenance procedures for service personnel only. 7.

Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. tested and approved to meet strict global safety standards with the use of specific Lexmark components. • • viii Service Manual .4085-001 Safety Information • This product is designed. le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • • Consignes de Sécurité • Ce produit a été conçu. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. The safety features of some parts may not always be obvious. Professional service personnel should understand this and take necessary precautions. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques. Lexmark is not responsible for the use of other replacement parts.

wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. deve. • • Safety Information ix . Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Durante lo smontaggio e la manutenzione di questo prodotto. die nicht von Lexmark sind. adottare le precauzioni necessarie. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Il personale di assistenza autorizzato. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.4085-001 Norme di sicurezza • Il prodotto è stato progettato. • • Sicherheitshinweise • Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet. quindi. Sofern Teile eingesetzt werden. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen. il rischio di subire scosse elettriche e danni alla persona è più elevato.

• • x Service Manual . verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Lexmark no se hace responsable del uso de otras piezas de recambio. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. • • Informações de Segurança • Este produto foi concebido. testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. A Lexmark não é responsável pela utilização de outros componentes de substituição.4085-001 Pautas de Seguridad • Este producto se ha diseñado. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark.4085-001 Informació de Seguretat • Aquest producte està dissenyat. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • • Safety Information xi . La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d’aquest producte. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

4085-001 xii Service Manual .

Printing Mode Maximum Average (approximately) 90 Watts . narrow-format. The printheads provide color and true black printing. The black printhead has 640 nozzles and the color printhead has 320 nozzles for each color. determines the overall quality and capability of the printer.4085-001 1. It is intended for use by single users or by small workgroups shared using an external network solution or peer-to-peer networking. thermal inkjet printer designed to print high quality text.Power Saver including options (conforms to Energy • • Star Sleep Mode specification in Power Saver). Power Consumption • 2 Watts .Off Mode (conforms to Blue Angel power specifications in the Off Mode) • <20 Watts . The printer goes to low power mode when not printing. in the printhead. 50 Watts . This printer features parallel and USB standard connectivity. graphics. The number and size of inkjets or nozzles.Printing Mode Peak (approximately) General Information 1-1 . and images on a wide variety of media. General Information The Lexmark™ J110 printer is a high-performance.

The user is directed. symptom index.0 V +32. Use the error indicator charts. service checks.1 A for 100ms or less and 3. Peak (1) +36 V +36. and diagnostic aids to determine the symptom and repair the failure.5 Amps Min. 40 Watts Output (50 Watts input) Outputs: Output Name +5 V Nominal Voltage + 5.4 V +39. 2. The +36 V output can supply peak currents of 2. 1-2 Service Manual .4085-001 Internal Power Supply Specifications Built-in Universal Power Supply.8 V Maximum Voltage +5.6 Amps Max. perform tests as needed to verify the repair. Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. After you complete the repair.1 V Minimum Voltage +4. Avg.1 Amps Peak (1) 3.2 A for 30 ms or less.0 A is long term average current. (1) 2. in the Printer Control program. 1.1 Amps Min.25 V Load Range 0.0 Amps Max. to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge. This printer can be serviced without being connected to a host computer. 1.0 Amps Peak 0.2 Amps Max.6 V Note: Current of 1.

4085-001 Tools Required For Service • • • • • Analog or digital multimeter Parallel wrap plug P/N 1319128 Pliers: diagonal and needle-nose Screwdrivers: #1 and #2 Phillips Magnet Abbreviations EOF ESD FRU LED MPF NPA POR POST SIMM RAM ROM V ac V dc End of Forms Electrostatic Discharge Field Replaceable Unit Light-Emitting Diode Multi-Purpose Feeder Network Printer Alliance Power-On Reset Power-On Self Test Single In-line Memory Module Random Access Memory Read Only Memory Volts alternating current Volts direct current General Information 1-3 .

on the front right side of your printer. Operator Panel Display Power Indicator Light Menu Select Return Go Stop Power Indicator States The power indicator light gives information about the status of your printer. six buttons (Menu is actually two buttons). Printer is powered on and the printer is busy. which are designated on the front cover. has a 2-line by 16-character liquid crystal display (LCD). 1-4 Service Manual . Power Indicator Off On Flashing Meaning Printer is powered off. The buttons have fixed functions.4085-001 Operator Panel and Menus Using the Operator Panel The operator panel. and one power indicator light. Printer is powered on and the printer is idle.

Note: Buttons act upon the information that appears on the second line of the operator panel. press and hold Menu>. If a menu item setting such as Tray 2 is displayed. then Select opens the menu and displays the first printer setting contained in the menu. To automatically increment a numerical printer setting. then Select saves the selection as the new default setting for Paper Source. press and hold Menu<. This button is used to place the printer in the Ready state after an off line situation. such as Paper Menu. Select the menu selection displayed on the second line of the display. then Select opens the item and displays the default setting. and it can also be used to clear most Attendance messages. Release Menu< when the number you want is displayed. change printer settings. The last menu group is displayed. Press the Select button. Once a menu group is active. press Menu> to step to the next selection. Menu> Menu< Select General Information 1-5 . Press Menu< to enter a menu group.4085-001 Operator Panel Button Functions Use the six operator panel buttons to open a menu. Once a menu group is active. Button Go Function Press the Go button. Press Menu> to enter a menu group. The first menu in the menu group is displayed. and respond to printer messages. If a menu item such as Paper Source is displayed. The printer displays the Saved message momentarily and then returns to the menu item level. scroll through a list of values. Release Menu> when the number you want is displayed. For instance. press Menu< to step to the previous selection. The following table describes the functions of each button. Go can be used to exit the menus. To automatically decrement a numerical printer setting. If a menu is displayed.

the printer is ready to receive a print job. Returns to the previous menu level. If at the top level of the menus. Stop suspends job activity and displays the Not Ready message. Press the Stop button. • Attendance messages indicate printer errors that you must • resolve. Service messages indicate printer failures that may require servicing.4085-001 Button Return Function Press the Return button. Job activity resumes when Go is pressed. Stop Printer Messages The operator panel displays three types of messages: • Status messages provide information about the current state of the printer. When the Ready status message displays. then it functions like Go. While a job is printing. the Busy status message appears on the first line of the operator panel display. 1-6 Service Manual .

but they only affect printer function when you use the specified printer language. General Information 1-7 . Changes made from a software application or driver override the user default settings made from the printer operator panel. Some menus appear only if a specific option is installed in the printer. These settings are active until new ones are stored or the factory defaults are restored. the asterisk moves next to the selected setting to identify it as the current user default. Other menu items may only be effective for a particular printer language.4085-001 Operator Panel Menus Menus make it easy for you to change printer settings. An asterisk (*) next to a value indicates the original factory default setting and may vary for different countries. You can select these values at any time. When you select a new setting from the operator panel.

The printer returns to the Ready state after the menu settings page prints. verify that they are listed on the menu settings page under “Installed Features. Note: Before printing the menu settings page. unplug the power cord and reinstall the option. Press Menu> or <Menu to enter the menus. 3. 4. Press Select. 6. Make sure the printer is plugged in and the Ready status message appears on the display. 5. 2.” If an option you installed does not appear on the page. You can use this page to verify that the printer options are properly installed and the printer settings are properly set. Press Select to select Print Menus. make sure the Paper Type setting for the source is Plain Paper. To print a menu settings page: 1.4085-001 Printing the Menu Settings Page The menu settings page shows current settings for the menus and a list of installed options. 1-8 Service Manual . The message Printing Menu Settings appears and remains on the operator panel display until the page prints. Utilities Menu appears on the first line and Print Menus is on the second line. If you installed options. Continue to press and release Menu> until you see Utilities Menu.

2. Changes made from a software application override the user default settings made from the printer operator panel. Press Select. Note: User default settings remain in effect until you save new settings or restore the factory defaults. 9. 3. An asterisk (*) appears beside the current user default setting for that menu item. The display shows the new setting for one second and then clears. Press Menu> or <Menu until the value you need appears on the second line of the display. 4. Press Select. To select a new value as the default setting: 1. Press Menu> or <Menu until the menu item you need appears on the display. Note: Some menu items have sub-menus. Press Select. Press Return to go back to previous menus or menu items and set new default settings.4085-001 Changing Printer Settings You can use the operator panel to change printer settings and customize your printer to meet your specific needs. General Information 1-9 . Continue to press and release Menu> or <Menu until the menu you need appears on the second line of the display. The menu opens and the first menu item in the menu appears on the second line of the display. 8. press Menu> or <Menu to enter the menus. 6. 5. An asterisk (*) appears beside the value to indicate that it is now the user default setting. then the previous list of menu items appears on the operator panel display. You must select another menu (such as Tray 1 Type) before the available values display. 7. The Saved message displays. Press Go to return to Ready if this is the last printer setting you want to change. From the Ready state.

When the printer self test completes. turn on the printer. 3. 2. the Menus Disabled message appears.4085-001 Disabling the Operator Panel Menus To disable the menus so that changes cannot be made to the printer default settings: 1. Turn off power. Release the buttons when Performing Self Test appears. 1-10 Service Manual . If you press Menu> or <Menu. the Ready status message appears. While pressing Go and Stop.

and take the indicated action. symptom tables.4085-001 2. Diagnostic Information 2-1 . service checks. Turn the printer off and then back on to clear service errors. Diagnostic Information Use the error indicator table. Start Service error indications are displayed on the operator panel. locate the error number in the “Error Indicator Table” on page 2-3 . and diagnostic aids to determine the printer failure. If your printer displays an error indication.

The original 9XX or 2XX error message must be displayed for this function to operate. and support engineer resolve the problem. The jam jog function helps clear any pages that have been stopped mid-way through the paper path. Note: Jam Jog will not work while debug data is displayed on the panel. The first screen of debug information appears. customer engineer. To access this information. complete the following steps: 1. Press and hold Return and then press and release Select. Once the end of the debug data is reached. In general. The only recovery is to turn off the printer. the original service message is displayed. Write down this information. However. the printer stops printing. and the printer needs servicing. it may be possible to power the printer off and back on to temporarily recover from the error condition if it is intermittent in nature. service errors are non-recoverable. This information may help the Customer Support Center.4085-001 Service Messages These messages are displayed whenever the printer is in the Operator Intervention state. Jam Jog Function When in any 9XX error condition. 2-2 Service Manual . Continue pressing Return+Select until each screen of debug data is obtained. 2. you can press the Menu> button to implement the jam jog function. When a Service Message occurs. Accessing Additional Debug Information for Service Errors Additional debug information may be available for the specific service error being displayed.

A failure occurred when programming this block. 906 Engine Board XX 10 ASIC RAM failure 20 Engine Processor failure 21 Boot Code Checksum failure 22 Engine ASIC failure 23 Boot / Engine Card incompatibility Replace the engine board. Replace the engine board.4085-001 Error Indicator Table Error 900 Symptom RIP Software Action Perform the “RIP Card Service Check” on page 2-65 . Replace the RIP card. See the “Engine Board / Cover Removal” on page 4-14 . 902 Engine Software 903 RIP Software 904 905 Service Options Interface Engine Flash XX 80 Flash Erase failure 81 Flash Programming failure 82 Flash . Diagnostic Information 2-3 . See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 .Invalid checksum on input data. Check RIP/Engine cable. See the “Engine Board / Cover Removal” on page 4-14 . Check cables. Replace the engine board. Replace the board in the optional tray. See the “Engine Board / Cover Removal” on page 4-14 . 83 Flash .

Replace index board. the engine board must be replaced. See “Index Card Assembly Removal” on page 4-22 . 2-4 Service Manual .4085-001 Error 907 Symptom Engine NVRAM 10 Invalid data in flash memory 20 NVRAM checksum failure 30 Flash data programming failure 40 Engine NVRAM is not present or is not responding 50 Password rejected by engine NVRAM Note: When the index card and encoder dial FRU needs replacing.Replace engine board.Replace index board. 30 . 910 Carrier System 10 Carrier Motor stall or loss of encoder signals 20 Encoder Quadrature error 30 Temperature Sense--------> Calibration failure 40 Carrier running backward 50 Carrier Velocity Overshoot 60 Starfire ASIC Reset failure 70 Printhead and Index Voltage Level failure This would be caused by printhead contacts or carrier card. Perform the “Carrier System Test” on page 3-32 .Replace engine board. Check cabling to index board. 908 Engine NVRAM 90 Decompression / Rebuild Failure Action Check cabling to index board. 20 . See “Index Card Assembly Removal” on page 4-22 .Replace index board. 40 and 50 . See “Engine Board /Cover Removal” on page 4-14 . and a 907-10 error code is present. Note: “Carrier Systems Test” would not find this. 10 .

921 922 Multi-Purpose Feeder Motor Motor stall or loss of Encoder signals 923 “Exit System” .Motor stall or loss of Encoder signals See “Index Card/Sensor Service Check” on page 2-68 .Ink Float Sensing Calibration failure Note: Many of the 930-938 are communication failures between the printheads and the carrier contacts as noted. Perform “Ink Level Sensor Test” on page 3-31 . Diagnostic Information 2-5 . Action Perform the “Index System Test” on page 3-33 . See “Index Motor Service Check” on page 2-57 . See “MultiPurpose Feeder (MPF) Motor and Sensor Service Check” on page 2-58 . If contact failures are suspected.Pick Motor stall or loss of Encoder signals PerfectFinish™ System . See “Entering CE Diagnostics Mode” on page 3-2 and “Maintenance Sled Test” on page 3-33 . If problem still exists. Check Motor and Encoder. Check Multi-Purpose Feeder Motor. This can be done by lightly placing a piece of low tack tape on the printhead tab circuit and inserting it in the carrier. If contamination is suspected. go to “Index System Test” on page 3-33 . See “Entering CE Diagnostics Mode” on page 3-2 . See “Index Motor Service Check” on page 2-57 . Clean the pogo pins only with a clean.4085-001 Error 915 Symptom Index System 10 Index Motor Stall or loss of Encoder signals 20 Encoder Wheel “once-perrevolution” sensor failure 30 Unable to calibrate Analog Sensor 40 Index Motor wired backward 920 “Feed Motor” .Cam Motor Homing failure “Maintenance System” Maintenance Motor Homing failure 925 928 Ink Level System . go to “Index System Test” on page 3-33 . check alignment between the pogo pins and printhead tab circuit. remove the printhead and clean the contacts with a low-lint damp cloth. If problem still exists. lint-free cloth.

Check the printhead and tank memory chip placement. Try replacing the printheads before replacing the carrier. Replace printheads. See “Engine Board /Cover Removal” on page 4-14 . See “Carrier/Cable Retainer Removal” on page 4-48 .Contents of Printhead Memory are invalid Both Printheads . If problem remains. If failure still occurs. Try replacing both printheads. If tests fail. Check the printhead/ carrier contacts. See “Engine Board /Cover Removal” on page 4-14 .Contents of Printhead Memory are invalid Color Printhead . Action Check all contacts and cables. Check the carrier cable. If contents of printhead memory are still invalid.Failure measuring a calibration resistor.P-lines shorted or Substrate Heater shorted 931 Black Printhead . replace the engine board.Engine cannot communicate with Printhead Memory Color Printhead .Engine cannot communicate with Printhead Memory Check the printhead and tank contacts. 932 Black Printhead . Check carrier cables.P-lines shorted or Substrate Heater shorted Color Printheads . replace carrier.Check the carrier to engine cables.Engine cannot communicate with Printhead Memory Both Printheads . If the problem remains.Contents of Printhead Memory are invalid 933 Printhead System . If cable is OK. replace engine board. See the “Engine Board / Cover Removal” on page 4-14 . The debug data identifies the resistor being measured and the type of failure: value too low. replace the printheads. or value=zero. 2-6 Service Manual .4085-001 Error 930 Symptom Black Printhead . replace engine board. replace engine board. value too high.P-lines shorted or Substrate Heater shorted Both Printheads . See “Change Printheads” on page 3-4 .

See “Engine Board /Cover Removal” on page 4-14 . replace engine board. Try replacing the printheads before replacing carrier. If problem remains. replace carrier. See “Carrier/Cable Retainer Removal” on page 4-48 . Replace printhead. See “Change Printheads” on page 3-4 . If cable is OK. replace carrier. replace carrier assembly. replace carrier.4085-001 Error 934 Symptom Black Printhead Color Printheads Both Printheads TSR measurement indicates a cracked / open TSR or open connection. Check the printhead contacts. See “Carrier/Cable Retainer Removal” on page 4-48 . If problem remains. 938 Printhead Thermal System error Diagnostic Information 2-7 . See “Engine Board /Cover Removal” on page 4-14 . or value too high. replace engine board. If cable is OK. See “Carrier/Cable Retainer Removal” on page 4-48 . 936 Service Printhead System Failure zeroing the TSR measurement system. The debug data identifies the TSR that is open. If cable is OK. 935 Black Printhead Color Printheads Both Printheads Failure measuring a TSR value. See “Engine Board /Cover Removal” on page 4-14 . replace engine board. Try replacing the printheads before replacing carrier. Overheated. Check the carrier cable. If problem remains. Check the carrier cable. Action Check the carrier/ printhead contacts. Try replacing both printheads before replacing carrier. Check the carrier cable. If problem remains. The debug data identifies the TSR being measured and the type of failure: value too low.

NVRAM Chip failure Replace the RIP card. If the connections are good. Replace the RIP card.4085-001 Error 939 Symptom RIP to Engine communications failure Action Unplug and replug the AC power cord to see if the problem goes away. Note: The RIP software can cause a 939 error. 954 NVRAM Failure . See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . replace the engine board. See “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 .NVRAM CRC failure 955 Code ROM error Replace the RIP card. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . If the problem remains.Processor failure 957 RIP ASIC failure 2-8 Service Manual . replace the RIP card. 956 RIP Card . See “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . Check the RIP card cable connections. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . Replace the RIP card. Replace the RIP card. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . 953 NVRAM Failure . See “Engine Board /Cover Removal” on page 4-14 .

See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . 980 Tray 2 Communication Error Communication between Tray 2 and the Engine is unreliable. 985 Diagnostic Information 2-9 . Replace tray 2 card. Check engine to tray 2 cable and contacts.4085-001 Error 960 Symptom RAM Memory Error . Tray 2 Error Check connection between engine board and optional card. Look for PerfectFinish leaks.RAM soldered on the card is bad Action Replace the RIP card.

Action Press Menu> or Menu< to take the printer offline and access the Ready Menu group. No more data is processed from the host computer. The following function may be available via the Busy/ Waiting Menu group: -Reset Printer Note: The ready menu group is not accessible if Menu Lockout is turned on. Press Stop to take the printer offline.4085-001 User Status Messages User Status Message Ready Status The printer is ready to receive and process data from a host system. Press Go to return the printer to the previous state. The Not Ready message appears. 2-10 Service Manual . access is automatically granted to the Busy/Waiting menu group. Instead.

Note: Press Menu> or Menu< to access the Busy/Waiting Menu group.4085-001 User Status Message Busy Status The printer is processing data and/ or printing pages. The printer is online while the Busy/ Waiting Menu group is active. The Not Ready message appears. If no function in the Busy/Waiting group is available. the printer processes all of the paper currently in motion in the printer’s paper path. The Power indicator blinks while the printer is processing data. No more data is processed from the host computer. Diagnostic Information 2-11 . however. Press Go to return the printer to the previous state. The following functions may be available using the Busy/ Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Action Press Stop to take the printer offline. the Menus Disabled message is temporarily shown when you press Menu> or Menu<.

Selection of Go does not terminate the current print job. the printer processes all the paper in the printer’s paper path. however. No more data is processed from the host computer. Action Press Go to print the contents of the printer’s buffer. Press Go to return the printer to the previous state. Note: The Go press is ignored when Print Buffer Control is Off. Press Menu> or Menu< to access the Busy/ Waiting Menu group. Press Stop to take the printer offline. The Not Ready message appears. The following functions may be available using the Busy/Waiting Menu group: -Cancel Job -Reset Printer -Print Buffer 2-12 Service Manual . The printer will be online while the Busy/Waiting Menu group is active.4085-001 User Status Message Waiting Status The Waiting is displayed until the current job is terminated or until additional data is received on the active link.

or if x=0 on the standard network interface. the printer automatically shows the next highest priority warning message. The copying message is shown when the printer is drawing and processing data originating from an OptraImage™ scanner connected to the printer by a network adapter. Diagnostic Information 2-13 . empty. or missing. Parallel USB<x> The host interface from which the printer is currently drawing and processing data. Once the current warning condition is cleared. Those messages designated by <x> indicate the active interface is connected to the printer by PCI connector x.4085-001 Warning Messages As shown in each of the Status Screens. The associated network interface which exists between the printer and network adapter is used for data transmission. Panel Message Supplies Available on Status Screen • • • • • • • • • • • • Ready Hex Trace Ready Power Saver Busy Resolution Reduced Waiting Ready Hex Trace Ready Power Saver Busy Resolution Reduced Waiting Description One or more of the printer supply items has either reached its life warning or is exhausted and/or one of the paper sources is low. only one warning message can be displayed at any one time. If an event occurs which causes a higher priority warning. Those messages designated by <x><y> indicate the active interface is connected to the printer by a channel y on PCI connector x. Those messages which are not designated by a <x> imply the active host interface is a standard interface. the higher priority warning message replaces the lower priority warning message. Note: There is no Copying host interface.

No buttons are active while this message is displayed. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. If no function in the Busy/Waiting group is available. Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Cleaning Printheads Appears after Cleaning Printheads is selected.4085-001 Status Messages These messages provide the operator with information on the current state of the printer. Canceling Job Press Menu> or Menu< to access the Busy/ Waiting Menu group. Action No buttons are active while this message is displayed. Status Message Activating Menu Changes Status The printer is being reset to activate a printer setting changed in the menus. 2-14 Service Manual . This message is displayed until the cancel operation is complete. The printer is online while the Busy/Waiting Menu group is active. Appears after the Cancel Job operation is selected.

If the Menu Lockout value is changed to Off (Panel Menus=Enable). Action No buttons are active while this message is displayed. Flushing Buffer No buttons are active while this message is displayed. Action No buttons are active while this message is displayed. The interpreter is flushing the currently active job until an End Of Job is found or until no data has been received on the active host interface for 5 seconds. Diagnostic Information 2-15 . then the Disabling message is displayed. Status Message Activating Menu Changes Status The printer is being reset to activate a printer setting changed in the menus. If the Menu Lockout value is changed to On (Panel Menus=Disable). then the Enabling message is displayed. A representation of the operator panel when the printer is flushing a print job.4085-001 Status Message Disabling/Enabling Menus Status A representation of the operator panel when the user has modified the Menu Lockout printer setting using the Configuration Menu Group.

This message is displayed until the cancel operation is complete. Cleaning Printheads Appears after Cleaning Printheads is selected. however. The printer is online while the Busy/Waiting Menu group is active. following the “Performing Self Test” message or during printing.” The printer will not post “Ready” until Go is pressed. 2-16 Service Manual . the printer will post “Not Ready. Typically this menu is used to access the Reset functions of view the printer Supplies status. The printer is online while the Busy/Waiting Menu group is active. If no function in the Busy/Waiting group is available. The Stop button is available. Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Action Press Menu> or Menu< to access the Busy/ Waiting Menu group. Action Press Menu> or Menu< to access the Busy/ Waiting Menu group for menu details. Status Message Printer Calibrating Status A representation of the operator panel when the printer is initializing the mechanical subsystems at POR (Power-On Reset).4085-001 Status Message Cancelling Job Status Appears after the Cancel Job operation is selected. The duration of this message varies depending on the level in the lower PerfectFinish vessel. No buttons are active while this message is displayed. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed.

Action No buttons are active while this message is displayed. Action No buttons are active while this message is displayed.4085-001 Status Message Invalid Engine Code Status A representation of the operator panel when either the engine code has not been programmed or has been programmed but is invalid. Once this condition occurs. the Ready and Busy messages will not be displayed until valid Engine code exits. Diagnostic Information 2-17 . Status Message Menus Disabled Status Appears when the Menu> or Menu< button is pressed to access the Busy/ Waiting Menu group and all the available selections in the menu group have been disabled. Engine code can still be downloaded to the printer when this message is on the display.

4085-001 Status Message Not Ready Status A representation of the operator panel when the printer is in the Not Ready state. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. The printer is online while the Busy/Waiting Menu group is active. all timeouts are stopped. The following functions may be available using the Busy/ Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. In addition. All host links are marked as busy when the printer is Not Ready. 2-18 Service Manual . Press Menu> or Menu< to access the Busy/ Waiting Menu group. Action Press Go to take the printer out of the Not Ready state. If no function in the Busy/Waiting group is available.

the printer enters the Ready state. this is the last message shown before power is cut off to the RIP and engine.4085-001 Status Message Performing Self Test Status A representation of the operator panel during Power-On Self Test (POST). A representation of the operator panel during power-down cycle. The error conditions that could cause this are: -Paper Jams -Service Messages Action No buttons are active while this message is displayed. When the test is complete. In the event that no errors are found. Diagnostic Information 2-19 . Powering Down No buttons are active while this message is displayed. It is possible that an error condition could be detected that causes the printer to go into a different state. after the user has turned the machine off.

4085-001 Status Message Printing Menu Settings Status A representation of the operator panel when Print Menu Settings is selected from the menu. No more data is processed from the host computer. Press Menu> or Menu< to access the Busy/ Waiting Menu group. 2-20 Service Manual . the printer processes all of the paper in the printer’s paper path. The following functions may be available using the Busy/ Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. If no function in the Busy/Waiting group is available. The Not Ready message appears. Action Press Stop to take the printer offline. This message appears until the Print Menus page or pages are formatted and submitted to the print engine and then Busy is shown. Press Go to return the printer to the previous state. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. however. The printer is online while the Busy/Waiting Menu group is active.

Diagnostic Information 2-21 .4085-001 Status Message Printing Alignment Page Status A representation of the operator panel when Align Printheads is selected from the menu. If no function in the Busy/Waiting group is available. Action Press Menu> or Menu< to access the Busy/ Waiting Menu group. The printer is online while the Busy/Waiting Menu group is active. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. This message appears until the Alignment page is formatted and submitted to the print engine and then Busy is shown. The following functions may be available using the Busy/ Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group.

Prog Engine Code DO NOT POWER OFF Note: This message may display after replacing the index card and encoder disk FRU. If no function in the Busy/Waiting group is available. Action Press Menu> or Menu< to access the Busy/ Waiting Menu group. This message appears until the Clean Printheads test page is formatted and submitted to the print engine and then Busy is shown. The printer is online while the Busy/Waiting Menu group is active. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. the printer returns to the Ready screen. 2-22 Service Manual . A representation of the operator panel whenever new code is programmed in the engine flash. The following functions may be available using the Busy/ Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. I No buttons are active while this message is displayed.4085-001 Status Message Printing Test Page Status A representation of the operator panel when Clean Printheads is selected from the menu. When the programming is complete.

4085-001 Status Message Programming System Code Status A representation of the operator panel when new code is programmed in the RIP code flash. A representation of the operator panel after the operator has initiated one or two Factory Defaults operations. Action No buttons are active while this message is displayed. The printer resets with the PowerOn Reset defaults. A representation of the operator panel during a Printer Reset. This message is shown until the programming is complete. the printer performs a Power-On Reset. Restoring Factory Defaults No buttons are active while this message is displayed. Resetting Printer No buttons are active while this message is displayed. Diagnostic Information 2-23 . When the programming is complete.

.G alignment values.. and K.4085-001 Attendance Messages These messages are displayed when the printer is in the Operator Intervention state. all host links are notified about the intervention required condition. The only exception is the PostScript Feed timeout. This timeout starts when the Load Paper message is displayed for the manual source. Enter the alignment value and press Select to continue to the next alignment value. All timeouts are stopped while the printer is in an operator intervention state. XXXX is a placeholder for some combination of C. A similar message is displayed for B. 2-24 Service Manual . When an operator intervention condition occurs. and yellow inks are empty. A similar message displays when the black. 89 Cartridge Empty XXXX This is a Type 4 error and can only be cleared by inserting a new ink cartridge. Action Press Go or Return to end the alignment operation. A representation of the operator panel when cyan ink empty occurs. The operator is provided with a description of the operator intervention condition. Attendance Message A Alignment = 8* Description A representation of the operator panel when Align Printheads is selected from the Utilities Menu and the printer is prompting the user for the “A” alignment value. In this representation.Y.M. magenta.

and K. A representation of the operator panel when an ink cartridge life expires. Diagnostic Information 2-25 . XXXX is a placeholder for some combination of C. A similar message appears when the black.4085-001 Attendance Message 88 Cartridge Low XXXX Description A representation of the operator panel when cyan ink low occurs and the Ink Alarm is activated.Y. Cartridge LIfe Expired XXXX Open the cover and replace the expired ink cartridge(s). and K. Action Press Go to clear the message. magenta and yellow inks are low.M. The XXXX is a placeholder for some combination of C.Y. the useful life of the cartridge is expired and the cartridge must be replaced. This means that although ink remains in the cartridge.M.

B2. Other Envelope Action Sources equipped with both size-sensing and media-present hardware: Load the requested size and/or paper type in the source indicated in the message. The new paper type. 2-26 Service Manual . Tray 2. If the requested type matches the type that is installed in the tray and the type is one of the custom types which has not been named. A5. 10 Envelope. One of the following sizes is left-justified on line 2: Letter. Go is ignored if the sensed size is incorrect or media is not present in the tray. If the source already contains the correct size and paper type. Universal. paper size. Legal. DL Envelope. C5 Envelope.4085-001 Attendance Message Change<input source> <size> Change<input source> <type><size> Description A representation of the operator panel when the printer is requesting the operator to change the media installed in one of the input sources. then the printer automatically clears the message and continue the job. A4. B5 Envelope. Executive. then press Go. The input source is displayed on line 1 and could be one of the following: Tray 1. MP Feeder. 9 Envelope. then only the size is displayed. Note: The printer assumes the user loaded the correct paper type. This situation occurs when the user changes the media in the source. 7 3/4 Envelope. and custom string settings are stored in NVRAM. If media is present in the source and the sensed size is correct. but forgets to change the paper type setting in the menus.

The printer automatically clears the message and continues the job. If the source already contains the correct paper size and type. Other Action Sources equipped mediapresent hardware ONLY: Load the requested size and/or type in the source indicated in the message. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. Transparency The requested size could be one of the following: Letter. The following functions may be available using the Busy/Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. To ignore the request and print on the media installed in the tray. press Go. A5. Coated. Legal. Card Stock. C5. 10. Colored. Labels. Letterhead. 7 3/4. If no function in the Busy/Waiting group is available. Some clipping may occur. Executive. Photo. 9. The requested type could be one of the following: Bond. B5. Envelope. press Select. B5. Go is ignored if media is not present in the tray.4085-001 Attendance Message Change<input source> <size> Change<input source> <type><size> (CONTINUED) Description In all other cases. Preprint. IronOn. This occurs when the user changes the media in the source. Press Menu> or Menu< to access the Busy/ Waiting Menu group. Glossy. Diagnostic Information 2-27 . both the type and size are displayed on line 2. Plain. but forgets to change the paper size and/or paper type settings in the menus. A4. Universal. DL.

on the paper installed in the tray. unless they have been overridden for the job as well. print quality parameters related to the print process are selected based on the installed type. 2-28 Service Manual . as it is formatted. However. some clipping may occur. By overriding the prompt. This means that all print quality parameters related to page formatting are selected based on the type requested by the interpreter. In addition. not the installed type. Do not post any further Change Paper prompts for this source for the remainder of the job. automatically override to the size and/or type installed in the source. not necessarily the media in the tray.4085-001 Overriding Change Prompts The size override function lets you override Change Prompts for any source for the remainder of a job. the page is printed as it is formatted. That is for subsequent pages from this source. the color tables used to create the bitmap are for the requested media. • Note: When a change prompt is overridden. Therefore. the user is requesting the printer to do the following: • Print the page. Note: Change Prompts is shown for other sources.

the device could still be attached to the printer. then turn the printer off. reattach or reconnect it. Otherwise. to clear a paper jam or to uninstall the device). remove the option. If the device is experiencing a hardware problem. and call for service. Diagnostic Information 2-29 . If the error occurs again. Action If the device was temporarily removed or not connected properly. then turn the printer off and back on. When the device is recognized. the printer automatically clears the attendance condition and continues.4085-001 Attendance Message Check Tray x Connection Check MPF Connection Description A representation of the operator panel when the printer loses communications with one of the following devices: -Tray 2 -Multi-Purpose Feeder This error could occur in two ways. The specified device could have been removed from the printer (for instance. but is experiencing a communications problem (Not fully connected or hardware failure).

The printer automatically clears the message and continues printing. 3. Close Cover Close the upper front door. Press Return to stop the cleaning operation. A similar message is shown if the printheads associated with bars 2. Action Press Go if the long clean needs to be performed on the printhead represented by bar 1. the printer continues to print. but at a lower carrier velocity.4085-001 Attendance Message Clean 1? =Go/Stop Description A representation of the operator panel when a Long Clean is requested and the printer is asking the user if the printhead that printed the bar label “1” needs to be cleaned. Press Stop if the long clean does not need to be performed on the printhead represented by bar 1. 2-30 Service Manual . If the cover is open while printing. A representation of the operator panel when the printer’s upper front door is open. and 4 need to be cleaned.

The missing ink cartridge(s) will be identified in the XXXX string. and K. and K. the XXX is a placeholder for some combination of C. In this representation. In fact. The service engineer should use this function to help diagnose the problem.4085-001 Attendance Message 31 Defective Cartridge XXXX Description A representation of the operator panel when the printer detects a defective ink cartridge. This could be the case if the ink cartridge has a missing or defective smart chip. Remove and reinstall the defective cartridge. 2. Open the cover and insert an ink cartridge where an ink cartridge was missing (the carrier will present itself at the ink cartridge change location.Y. The carrier appears at the ink cartridge change location. Inspect pogo pins for damage. The defective cartridge is identified in the XXXX string. In the representation above. 1. The service engineer should use this function to help diagnose the printer problem.M. Press and hold Select. Try POR. 31 Missing Cartridge XXXX A representation of the operator panel when the printer detects a missing ink cartridge. XXXX is a placeholder for some combination of C. Action Open the cover and replace the defective ink cartridge(s). and then press Return to display debug data for the engine microcode and the applicable smart options. Diagnostic Information 2-31 .M.Y. The engine firmware was either unable to communicate with the ink cartridge EEPROM or the ink cartridge EEPROM was corrupted. Press and hold Select and then press Return to display debug data for the engine microcode and the applicable smart options. 3. the Technical Support Center may request the user to invoke this function as well.

4085-001 Attendance Message 31 Missing Printhead XXXX Description A representation of the operator panel when the printer detects a missing printhead. 31 PerfectFinish Missing A representation of the operator panel when thin coat missing occurs. XXXX is a placeholder for either: YMC. Press Go to clear the message and clear the message. The service engineer would use this function to help diagnose the printer problem. Press and hold Select and then press Return to display debug data for the engine microcode and the applicable smart options. 2-32 Service Manual . In fact. the Technical Support Center may request the user to invoke this function as well. In the representation above. Insert the thin coat supply item. This message indicates that the supply item must be replaced. Action Open the cover and replace the defective printhead (the carrier will present itself at the printhead change location. The missing printhead(s) will be identified in the XXXX string.K or YMCK.

this message is shown. each time the power is cycled on. Once a connection is initially established. if the setting states a connection exists. The printer cannot distinguish between an adapter which is not sending any data and an adapter which has been disconnected. Diagnostic Information 2-33 . Action Press Go to clear the message. Then. The printer clears the setting stating an external network adapter connection exists and restarts. The External Network Adapter connection is lost after the power-on cycle is complete. If the adapter does not respond. the printer attempts to communicate with the adapter. Note: This error is only detected during the printer’s power-on cycle.4085-001 Attendance Message 54 Std Par ENA Connect Lost Description A representation of the operator panel when the printer detects during its power-on cycle that the connection to an External Network Adapter has been lost. this error is not detected. a printer setting is modified to note a connection exists.

A representation of the operator panel when the printer is flushing a print job. It can also be displayed when a print job is sent to the printer in PostScript or PCL 5 emulations. The microcode data is discarded and must be re-transmitted from the host computer. Flushing Buffer No buttons are active while this message is displayed. The interpreter is flushing the currently active job until an End Of Job is found or until no data has been received on the active host interface for 5 seconds. 2-34 Service Manual . Action Press Go to clear the message. This message is commonly displayed when the Lexgear interpreter receives a print job with data corruption.4085-001 Attendance Message 81 Engine Code CRC Failure Description A representation of the operator panel when microcode to be programmed in the engine flash code module has failed a CRC check.

The user should remove the manual duplex sheets and reinsert them (face up) into tray 1. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. Reinsert pages into tray 1 (face up) and press Go to continue printing the back sides. Press Menu> or Menu< to access the Busy/ Waiting Menu group.4085-001 Attendance Message 56 Std Parallel Port Disabled Description A representation of the operator panel when data is sent to the printer across a parallel port. or the printer is reset. reporting of further errors is suppressed until the menus are entered. Action Press Go to clear the message. Diagnostic Information 2-35 . Insert Duplex Pages & Press Go A representation of the operator panel when a manual duplex job has been sent to the printer and the printer has completed printing the front sides of the pages. Enable the parallel port. Once the error has been displayed for the first time. The following function may be available using the Busy/ Waiting Menu group: -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. but the parallel port is disabled. If no function in the Busy/Waiting group is available. The printer discards any data received on the parallel port.

4085-001 Attendance Message Load <input source> <size> Load <input source> <type><size> Description A representation of the operator panel when the indicated source is out of media. both the type and size are displayed on line 2. The printer automatically clears the message and continues the job. One of the following items is shown on line 2: In all cases. 10. Card Stock. Sources equipped mediapresent hardware ONLY: Load the requested size and/or type in the source indicated in the message. IronOn. DL. Envelope. Coated. A5. Other Action Sources equipped with both size-sensing and media-present hardware: Load the requested size and/or paper type in the source indicated in the message. A4. Universal. B5. MP Feeder. Photo. Glossy. Labels. Plain Preprint. Legal. The input source is displayed on line 1 and could be one of the following: Tray 1. 7 3/4. If media is present in the source and the sensed size is correct. The requested type could be one of the following: Bond. The following functions may be available using the Busy/Waiting Menu group: -Cancel Job -Reset Printer 2-36 Service Manual . Transparency The requested size could be one of the following: Letter. B5. Press Go to request that the printer check the sources again for the prompted size and type. Colored. Press Menu> or Menu< to access the Busy/ Waiting Menu group. then the printer automatically clears the message and continues the job. Executive. Tray 2. C5. 9. Letterhead.

Labels. The request may have come through a print job or from the operator panel.Glossy. Photo. 10. Other Action If no media exists in the Manual Slot or MP Feeder. 7 3/4.4085-001 Attendance Message Load Manual <size> Load Manual <type><size> Description A representation of the operator panel when the printer receives a request to manually feed paper or envelopes in the Manual Slot or MP Feeder. A5. both the type and size are displayed on line 2. If the MP Feeder is installed and if the correct media is already present in the MP Feeder. B5. C5. then press Go. 9. Card Stock. Note: The printer assumes the user loaded the correct paper size and type. The printer clears the message and continues the job. Coated. The paper size. The requested type could be one of the following: Bond. Colored. Transparency The requested size could be one of the following: Letter. A4. One of the following items is shown on line 2. IronOn. then manually feed a sheet. The printer does not post a Load Media prompt and continues the job without any action from the user. DL. Plain. The printer automatically clears the message and continues the job. this is an unsolicited manual feed. and custom string settings are stored in NVRAM for the requested manual source. Executive. Letterhead. paper type. Preprint. Note: If the MP Feeder is not installed and if the correct media is already present in the Manual Slot. In all cases. Universal. Diagnostic Information 2-37 . Legal. B5. Envelope.

the Menus Disabled message is temporarily shown when Menu> or Menu> is pressed. press Select.4085-001 Attendance Message Load Manual <size> Load Manual <type><size> (CONTINUED) Description Action To request the printer to pick the sheet from an automatic source. If no function in the Busy/Waiting group is available. 2-38 Service Manual . Press Menu> or Menu> to access the Busy/ Waiting Menu group. The following functions may be available using the Busy/Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting group.

POR. This message will be posted if the carrier handle stalls against the covers while printing.Y. The missing ink cartridge(s) is identified in the XXXX string. Press and hold Select and then press Return to display debug data for the engine microcode and the applicable smart options. 4. Ensure that the carrier handle snaps into the detents. and K. Diagnostic Information 2-39 . 2. In this representation. XXXX is a placeholder for some combination of C. 3. Reinstall the missing cartridge or remove and reinstall a cartridge that is already in place. 1. Check for bent or damaged ink tank pogo pins. Action Open the cover and insert an ink cartridge where an ink cartridge is missing.4085-001 Attendance Message 31 Missing Cartridge XXXX Description A representation of the operator panel when the printer detects a missing ink cartridge.M.

Action Check printhead to carrier contacts. Open the door and change the supply item. and other data in RAM. In this representation. Some data loss occurs. The following functions may be available using the Busy Waiting Menu group: -Cancel Job -Reset Printer 2-40 Service Manual . Open Cover 38 Memory Full Press Go to clear the message and continue processing the job. Press and hold Select and then press Return to display debug data for the engine microcode and the applicable smart options. • Simplify your print job. XXXX is a placeholder for either: YMC.4085-001 Attendance Message 31 Missing Printhead XXXX Description A representation of the operator panel when the printer detects a missing printhead. A representation of the operator panel when the user has requested an ink cartridge change or a printhead change. macros. A representation of the operator panel when the printer is processing an incoming job and there is not enough memory available to continue processing the job. • Install additional memory. Determine how to make more memory available to your print job: • Delete fonts. Press Menu> or Menu< to access the Busy/ Waiting Menu group.K or YMCK. Press Go or Return to cancel the operation. The missing printhead(s) are identified in the XXXX string. Open the cover and replace the defective printhead.

201 Paper Jam (Printer Input Roller Sensor) Paper is jammed prior to the printer input roller sensor (nonPerfectFinish path). Press and hold Select and then press Return to display debug data for the engine microcode and the applicable smart options. Remove tray 1 and clear the jam. Open the cover and clear the jam. 203 Paper Jam (Printer Input Sensor) Paper is jammed over the input sensor. Each message also instructs the customer what action to take to resolve the jam or where in the printer to look to find the jammed paper.4085-001 Paper Jams Multiple paper jam messages exist for this printer. The Customer Support Center may request the user to complete this function as well. Most paper jam messages have a unique error number. Remove tray 1 and clear the jam. • press Go to resume printing. The service engineer should use this function to help diagnose the problem. The following actions can be taken while this message is displayed: • Once all the jammed pages are cleared from the paper path. Note: Press Menu> to perform a “jog” function to help free the jammed sheet. Diagnostic Information 2-41 . This applies to the following paper jams: 200 Paper Jam (Printer Staging Sensor) Paper is jammed prior to the printer staging sensor.

209 Paper Jam (Printer Input Roller Sensor) Paper is jammed prior to the printer input roller sensor. Open the cover and clear the jam. 207 Paper Jam (Fail to make Input Roller Sensor . Open the cover and clear the jam. 222 Paper Jam -Tray 2 Paper is jammed in tray 2. 221 Paper Jam -Tray 2 Paper was picked from tray 2 and is jammed over the feed sensor in tray 2. 2-42 Service Manual . 205 Paper Jam (Printer Input Roller Sensor) Paper is jammed prior to the printer input roller sensor (PerfectFinish path).4085-001 204 Paper Jam (Printer Staging Sensor) Paper is jammed over the staging sensor. 206 Paper Jam (Fail to make Input Roller Sensor . 220 Paper Jam -Tray 2 Paper was picked from tray 2 but did not arrive at the feed sensor in tray 2.PerfectFinish) Paper is jammed prior to the printer input roller sensor (PerfectFinish path). Remove tray 1 and clear the jam.Non PerfectFinish) Paper is jammed prior to the printer input roller sensor (non PerfectFinish path). 208 Paper Jam (Fail to make Staging Sensor .Tray 2 (PerfectFinish) Paper is jammed prior to the staging sensor (PerfectFinish). Check Tray 2.

251 Paper Jam (MPF) Paper was picked from the MPF but did not arrive at the input roller sensor. Diagnostic Information 2-43 .4085-001 250 Paper Jam (MPF) Paper was picked from the MPF but did not arrive at the input roller sensor.

This message indicates that the supply item must be replaced. The message appears again at the beginning of every subsequent job until the empty condition is cleared. The following actions can be taken while this message is displayed: • Press Go to clear the message and override the message. The following functions may be available using the Busy/ Waiting Menu – Cancel Job 2-44 Service Manual . The following actions can be taken while this message is displayed: • Press Go to clear the error and continue printing pages. This error can only occur when the printer does not know the actual paper size that is loaded in a tray. For the rest of the current job. • Press Menu> or Menu< to access the Busy/Waiting Menu group. the printer prints without PerfectFinish. Press Go to clear the message and override the message. then the operator may have entered the wrong size in the paper size menu. then the paper stop could be in the wrong position. If the tray is not capable of auto-size sensing. If the tray has auto-size capabilities. Replace the PerfectFinish supply item.4085-001 PerfectFinish Empty 87 PerfectFinish Empty The above is a representation of the operator panel when PerfectFinish empty occurs. • Short Paper 34 Short Paper The above is a representation of the operator panel when the paper length is too short to print the data as formatted.

Note: If no function in the Busy/Waiting group is available. See “Change Printheads” on page 3-4 . M. XXXX indicates which of the C. Unsupported Ink Cartridge 32 Unsupported Cartridge XXXX The above is a representation of the operator panel when the top cover is closed and an unsupported ink cartridge is detected (for example.4085-001 – Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. It may take the printer several seconds to determine if a print head is supported. Diagnostic Information 2-45 . It may take the printer several seconds to determine if the ink cartridge is supported. See “Change Ink Cartridges” on page 3-4 . XX indicates which of the K or C(MY) printheads are unsupported. the software keys of the printer and printhead do not match). the software keys of the printer and ink cartridge do not match). The following actions can be taken while this message is displayed: • Remove the unsupported ink cartridge. Y or K ink cartridges are unsupported. Unsupported Printhead 32 Unsupported Printhead XX The above is a representation of the operator panel when the top cover is closed and an unsupported printhead is detected (for example. The following actions can be taken while this message is displayed: Remove the unsupported printhead. the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed.

After the condition is cleared. In other words. Furthermore. the printer finishes printing all pages in the paper path. the printer immediately stops and an attendance message is displayed. none of the pages printed before the attendance message will be reprinted. the printer resumes printing the pages that were left in the paper path.When a Type 1 condition occurs during a job. After the condition is cleared.4085-001 Error Recovery from Attendance Conditions The following table indicates how the printer acts when each of the attendance/error conditions occurs. some data loss may occur on the pages. In other words. it may pick a few additional pages if they had already been committed to be printed.When a Type 2 condition occurs during a job. Type 3 . After the condition is cleared. none of the pages printed before the attendance message will be reprinted. the printer resumes printing the next page in sequence. Type 2 . See “Error Recovery from Attendance Conditions” on page 2-46 . the printer displays the attendance message. Once the pages are printed. Attendance conditions can be categorized into these distinct groups: • Type 1 .When a Type 3 condition occurs. the printer resumes printing the next page in sequence. the printer finishes printing all pages in the paper path before displaying the attendance message. All pages in the paper path must be manually cleared by the user. Depending on the specific condition. • • 2-46 Service Manual .

4085-001 Error Recovery from Attendance Conditions Auto Continue Available No No No No Sound Alarm (if Enabled) No Yes Yes Yes Attendance Condition Error Type A Alignment Cartridge Life Expired <cart(s)> Cartridge Life Warning <cart(s)> Change <src> <size> Change <src> <type> <size> Clean X? Go/Stop Load <src> <size> Load <src> <type> <size> Load Manual <size> Load Manual <type> <size> Insert Duplex Pages & Press Go Close Cover a Open Cover Check Tray x Connection Install Tray x or Cancel Job 31 Defective Ink Cartridge 31 Missing Ink Cartridge 31 Missing Printhead 32 Unsupported Print Head 32 Unsupported Cartridge 34 Short Paper 38 Memory Full 54 Std Par ENA Connection Lost 56 Std Parallel Port Disabled Type 1 Type 1 Type 1 Type 1 Type 1 Type 2 No No No Yes Type 2 No Yes Type 1 N/A Type 1 Type 3 Type 3 Type 1 Type 1 Type 1 Type 1 Type 1 Type 1 b Type 1 b Type 1 Type 1 b No N/A No No No No No No No No Yes Yes Yes Yes Yes N/A No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Diagnostic Information 2-47 .

Expect data loss when this condition occurs. b 2-48 Service Manual .4085-001 Auto Continue Available No No Yes No No Sound Alarm (if Enabled) Yes Yes Yes (Ink Low Alarm) Yes Yes Attendance Condition Error Type 81 Engine Code CRC Failure 87 PerfectFinish Empty 88 Cartridge Low <cart(s)> 89 Cartridge Empty <cart(s)> 200 Paper Jam Check Tray 1 201 Paper Jam Check Tray 1 203 Paper Jam Open Cover 204 Paper Jam Open Cover 205 Paper Jam Check Tray 1 206 Paper Jam Check Tray 2 207 Paper Jam Check Tray 2 208 Paper Jam Check Tray 2 209 Paper Jam Check Tray 1 220 Paper Jam Check Tray 2 221 Paper Jam Check Tray 2 222 Paper Jam Check Tray 2 250 Paper Jam Check MPF 251 Paper Jam Check MPF a Type 1 Type 1 Type 1 Type 2 Type 3 The printer continues to print (if it was printing) when the cover is open. However the carrier moves at a lower velocity.

3. “Performing Self Test” is displayed on the operator panel and then turns off. Diagnostic Information 2-49 . 6. Turn on power switch. go to the “Symptom Tables” on page 2-51 . 4. The operator panel displays one row of rectangles followed by two rows of diamonds. 7. locate the symptom in the following table and take the indicated action. The index motor cycles and then stops. The printer indicator (green light) comes on.4085-001 Power-On Self Test (POST) Sequence 1. 8. 5. 2. Locate the symptom and take the indicated action. If your printer does not complete POST. Ready is displayed indicating that POST is complete. The maintenance motor cycles and then stop. The printer indicator (green light) stays on. If your printer completes POST with no errors.

2-50 Service Manual . paperfeed motor turns All diamonds on display Performing Self Test remains on display. See the “Operator Panel (LCD) Display Service Check” on page 2-60 . See the “Power Supply Service Check” on page 2-64 . no motors turn and performing self-test is displayed Printer inoperable See the “Power Supply Service Check” on page 2-64 . replace the carrier assembly.4085-001 Post Symptom Table Symptom Blank display. carrier moves. See the “Power Supply Service Check” on page 2-64 . See the “Carrier System Test” on page 3-32 . no motors turn Index motor does not turn Maintenance motor does not turn Carrier drives into side frame Action See the “Operator Panel (LCD) Display Service Check” on page 2-60 . See the “Operator Panel (LCD) Display Service Check” on page 2-60 . Printer indicator light does not come on or fails to stay on POST is incomplete. See the “Index Motor Service Check” on page 2-57 . If carrier system test fails. See the “Maintenance Station Service Checks” on page 2-56 . printer indicator light is on.

If okay. See the “Maintenance Sled Test” on page 3-33 .4085-001 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Action See the “Transport Service Check” on page 2-68 . Maintenance Station Problems Symptom • • • • Fails to cap the printhead Fails to clean the printhead Pump fails to work Maintenance assembly does not move • Maintenance assembly moves to forward position. Diagnostic Information 2-51 . replace RIP card. Carrier Transport Problems Symptom • • • • No carrier movement Slow carrier movement Carrier stops Carrier does not move to cartridge load position when opening access door • Carrier strikes left side frame. See the “Carrier System Test” on page 3-32 . Action See the “Maintenance Station Service Checks” on page 2-56 . then will not return • Access door switch does not work • Peristalic pump or motor does not work. See page 2-48. Communications Problems Symptom Printer not communicating with host computer Not able to print test page Action See the “Parallel Wrap Test” on page 3-25 . Check the USB cable and engine board cable connection.

motor attempts to turn Action See the “Paper Feed Service Check” on page 2-61 .4085-001 Operator Panel Problems Symptom Printer indicator light does not: • • • • Turn on Flash Turn off All diamonds Action See the “Operator Panel (LCD) Display Service Check” on page 2-60 . Paper Feed Problems Symptom Paper fails to stop at first print line • Fails to pick paper • Picks more than one sheet of paper • Picks paper but fails to feed • Paper jams • Paper fails to exit • Noisy paper feed • Paper skews • Paper does not feed. See “Paper feed pick assembly does not feed. motor does not turn • Paper does not feed . See the “Operator Panel (LCD) Display Service Check” on page 2-60 . One or two pels missing Only one button inoperative More than one button inoperative All diamonds on display Replace the operator panel assembly. paper feed pick motor does not turn” on page 2-62 . 2-52 Service Manual . See the “Operator Panel (Buttons) Service Check” on page 2-59 . Replace the operator panel assembly. Power Problems Symptom Printer inoperable Action See the “Power Supply Service Check” on page 2-64 .

4085-001 Print Quality Problems Symptom • • • • • • • • • Voids in characters Light print Prints off the page Fuzzy print Carrier moves but does not print Printhead drying prematurely Vertical alignment off Excessive ink flow (flooding) Horizontal banding Action See the “Print Quality Service Check” on page 2-66 . • Ink smearing • Vertical streaks on paper • Print lines crowded See the “Paper Feed Service Check” on page 2-61 . Diagnostic Information 2-53 .

Wipe Spit Purge 2-54 Service Manual . The maintenance carrier moves in concert with the printheads to accomplish the maintenance routines. Function Cap Description The maintenance station caps and protects the printheads from drying and subsequent failure of the nozzles for up to six months. The maintenance station wipes the nozzle plates to remove ink buildup and debris. pump and drivetrain) are mounted on a maintenance carrier that is driven front to back in the printer. It also manages the waste ink used during the nozzle spitting maintenance routine. spitting. a jetting function is performed to completely recover the nozzles from any debris left by the wiping process. The maintenance station provides an area (bottle) to collect the ink from the jetting function of the printheads. These functions include: capping. A clean printhead test page will be incorporated into this function to allow the customer to qualify print quality before and after the nozzle recovery procedure. The caps should last the 100K page life of the printer. wiping. The customer may be required to initiate a “clean printhead” routing to fully recover dried or clogged nozzles following a six-month capping period.4085-001 Service Checks Maintenance Functions The maintenance station’s function is to maintain the printhead jetting over the life of the head. This area also serves to minimize mist creation and promotes evaporation of the ink. This action is perpendicular to the printhead movement. purging and wet wiping. Customer initiated purge is available in the “long clean” operation initiated from the operator panel. The maintenance station provides a purging function to remove bubbles and soft plugs that clog the printhead nozzles. Most functional parts (except motor. The maintenance carrier moves to positions that actuate the various maintenance functions. Following the wipe function.

000 page life of the printer. This solvent also serves to lubricate the wipers to reduce wear and prevent ink from drying on the wiper edge. This will occur several time during the life of the printhead to facilitate the removal of ink debris. which can reduce wiper efficiency. Maintenance Sump Capacity Diagnostic Information 2-55 . The maintenance station will collect the waste ink in a container (bottle) with sufficient volume for the 100. The container will provide spill protection for a 15-degree tilt at maximum waste volume.4085-001 Function Wet Wipe Description The maintenance station applies a cleaning solvent to the edge of the printhead that will be wiped across the entire bottom surface of the printhead.

2. check connector and voltage at the motor. See “Peristaltic Pump Removal” on page 4-49 . Engine code software controls the step count from the home position to the various positions the maintenance carrier must move to accomplish the various maintenance tasks on the printheads. broken or dislodged parts. Utilizing cams and linkages. 2 Maintenance Motor Assembly Check for approximately +1. 3 Peristalic Pump 4 Maintenance Homing Sensor 5 Wiper 6 Cap 2-56 Service Manual . the various components on the maintenance carrier are actuated by the carrier motion.4085-001 Maintenance Station Service Checks FRU 1 Maintenance Station Assembly Action The maintenance carrier is driven in a front to rear motion by the maintenance stepper motor. replace sensor. If voltage is incorrect. Check for a loose or worn wiper. If voltage is correct. and 4 on connector (J3) on the engine board. replace the pump. If connection is good. Check the hose connections. A worn cap can cause the printhead nozzles to dry and clog. replace the engine board. If the access door switch does not work or carrier does not move. If okay. check (J3) connector pin number 7 for approximately +5 V. A homing sensor is provided at the rear of the maintenance station to home the maintenance carrier during power up. See “Maintenance Sled Test” on page 3-33 . Check for a loose or worn cap. replace the motor. A worn wiper can cause degraded print quality just after a maintenance cleaning. Check the maintenance station for worn. Check the maintenance carrier moves through its complete forward to back motion without binds. 3. check connection at the sensor.8 V dc at pins 1. If a short or bind is found. Check that the maintenance sensor is snapped securely into the maintenance station frame. Check for a short in motor and for binds. If voltage is correct.

Input Tray Tests” on page 3-27 and “Diagnostics (Mode 2) . See “Index System Test” on page 3-33 . chipped teeth. 2 Gears Check the gears for proper alignment.5 ohms: (J16-1) and (J16-2) If reading is incorrect. missing gear clip or worn gears. loose motor. replace the index motor. 3 Sensor Sensor Checks See “Diagnostics (Mode 2) . See the “Index Motor Assembly Removal” on page 4-33 .4085-001 Index Motor Service Check FRU 1 Index Motor Action Check the following motor pins for approximately 12.Base Sensor Tests” on page 3-29 . Diagnostic Information 2-57 .

Check for a voltage reading at connector (J10) pin 1 for approximately +36 V dc on the engine board. If the voltage is correct. Remove the left cover. Top view of the multi-purpose feeder connector pin numbers: 4 3 2 1 8 7 6 5 2-58 Service Manual . If the voltage is incorrect. If continuity exists. If the voltage is correct. check the continuity between each pin 1 and 5 to the motor case. with MPF installed and power on. 2. replace sensor. replace the motor. See “MP Feeder Sensor Test” on page 3-28 . Check for a reading of approximately 3. Remove the rear cover from the printer. Remove the feeder from the printer. replace the engine board. go to “Power Supply Service Check” on page 2-64 .7 ohm.4085-001 Multi-Purpose Feeder (MPF) Motor and Sensor Service Check 1. Remove the engine board cover. check pins 7 and 8 to ground at connector (J10) for a voltage reading of approximately 5 V dc each. replace the multi-purpose feeder motor. To check the sensor. 6. If the reading is incorrect. check between pins 1 and 5 on the motor connector for approximately 16. 3. If the symptom remains. go to step 5. If the voltage is incorrect. To check the motor. 7. replace the engine board. If the reading is correct. 4. 5. Install the multi-purpose feeder. If ohm reading is not correct. remove the multi-purpose feeder and check between the motor connector pins 4 and 8 with the negative meter lead on pin 4 and positive lead on pin 8.8 ohms.

4085-001 Operator Panel (Buttons) Service Check FRU 1 Operator Panel Assembly Engine Board Operator Panel Assembly Action If any button fails the button test. check the continuity of the operator panel cable. be sure the voltage at (J4) pins 1. If correct. See “Button Test” on page 3-23 . 3 and 5 measures +5 V dc. replace the operator panel assembly. If the voltage is incorrect. 2. 2 Diagnostic Information 2-59 . replace the engine board. With the operator panel connected to the engine board. If the voltage is correct. Replace the operator panel cable if continuity is incorrect. replace the operator panel assembly.

carrier moves. 2-60 Service Manual . Run the “DRAM Memory Test” on page 3-23 . 2 LCD Options Service Check DRAM Memory Option(s) This service check is the same as the flash memory option service check.printer indicator light On. • Operator panel display blank .4085-001 Operator Panel (LCD) Display Service Check Note: Be sure the operator cable is properly installed at the engine board (J4) and at the operator panel. 2. If incorrect. If the voltage is correct. FRU 1 Engine Board Action Disconnect connector (J4) from the engine board and verify the voltage at approximately +9 V dc at pins 1. replace the RIP card. replace the engine board.printer indicator light Off. paper feed motor turns. see “LCD Hardware Test” on page 3-22 . • Operator panel display blank . replace the operator panel. If the test fails. Check the continuity of the cable and replace if necessary. 3 and 5. To check LCD. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 .

4085-001

Paper Feed Service Check
Note: Be sure the printer is unplugged from the AC outlet before performing this service check.

If you are experiencing a paper jam: 1. Check the 200 error code paper jams. See “Paper Jams” on page 2-41 . 2. Check the entire paper path for obstructions. 3. Be sure the input tray contains not more than 150 sheets of paper and the manual tray not more than 100. 4. Be sure the correct type of paper is being used. 5. Check for static in the paper. 6. Ensure the correct position of the left paper adjuster guide assembly.
FRU 1 Gears Action Check for binds in the gear train and paper feed mechanism by rotating the large feed roll by hand. Check all gears for correct installation and signs of wear or damage. If there is a bind, isolate it by removing one of the small idler gears on the inside of the left side frame. Replace any worn or binding gears or rollers. 2 Paper Path See “Paper Jams” on page 2-41 .

Diagnostic Information 2-61

4085-001 Paper feed pick assembly does not feed, paper feed pick motor does not turn
Note: A noisy or chattering motor or a motor that fails to turn can be caused by:

• • • • •

A defective motor A bind in the paper feed mechanism Defective gears Defective engine board Defective power supply
Action Check the power supply. See the “Power Supply Service Check” on page 2-64 . If the power supply voltage is incorrect, replace the power supply. Disconnect (J6) from the engine board. With the power on, check the voltage between pins 6, 10, and ground. The voltage at pin 6 should be approximately +35 V dc. The voltage at pin 10 should be approximately +5 V dc. If either of these readings are incorrect, replace the engine board. Check continuity between (J2) on the RIP card and (J14) on the engine board. If correct, replace the engine board. If incorrect, go to step 3. Disconnect (J6). Check between 6 and 7 on the connector for approximately 27.8 ohms. If reading is incorrect, replace the paper feed pick motor assembly. If reading is correct, check the continuity between each 6 and 7 to the motor case. If continuity exists, replace the paper feed pick motor assembly. Check the index motor connector J16 pin 2 to ground for approximately 27 volts. If voltage is incorrect, replace the system board. If reading is correct, check the continuity. See “Index Motor Service Check” on page 2-57 . If symptom remains, go to step 4. Note: If a short exists in the paper feed motor, damage to the engine board drivers and power supply may occur.

FRU 1 Power Supply

2

Engine Board

3

Paper Feed Pick Motor

Index Motor

4

Tray 1 Sensor Check

See “Tray 1 Sensor Test” on page 3-27 . If test fails, replace sensor.

2-62 Service Manual

4085-001
FRU 5 RIP Card Cable Action Check the continuity of the RIP card cable. If incorrect, replace the cable. If correct, replace the RIP card.

Optional tray 2 paper feed pick assembly does not feed, paper feed pick motor does not turn
Note: A noisy or chattering motor or a motor that fails to turn can be caused by:

• • • • •

A defective motor A bind in the paper feed mechanism Defective gears Defective engine board Defective power supply (+62 V dc)
Action Check the power supply. See the “Power Supply Service Check” on page 2-64 . If the power supply voltage is incorrect, replace the power supply. Check the position of tray 2 to insure that the paper port connectors are attached correctly. With the power on, check for the following readings: (J4) pin 1 to ground = 35 V dc (J4) pin 3 to ground = 5 V dc (J4) pin 5 to ground = 5 V dc (J4) pin 7 to ground = 5 V dc If voltage is incorrect, check the engine board and replace if needed. If voltage is correct, go to step 3.

FRU 1 Power Supply

2

Tray 2 Card

Diagnostic Information 2-63

4085-001
FRU 3 Paper Feed Pick Motor Action With the power on, check for the following readings: (J3) pin 3 to ground = 5 V dc (J3) pin 6 to ground = 35 V dc (J3) pin 7 to ground = 35 V dc (J3) pin 10 to ground = 5 V dc If voltage is incorrect, replace tray 2 card. If voltage is correct, disconnect (J3). Check between 6 and 7 on the connector for approximately 11.8 ohms. If reading is incorrect, replace the paper feed pick motor assembly. If reading is correct, check the continuity between each 6 and 7 to the motor case. If continuity exists, replace the paper feed pick motor assembly. Paper Feed Motor With the power on, check the voltage at (J1) paper feed motor connector. The voltage at each pin should read approximately 34 V dc. If voltage is correct check continuity. If continuity is incorrect, replace the paper feed motor. If symptom remains, go to step 4. Note: If a short exists in the paper feed motor, damage to the engine board drivers and power supply may occur. 4 5 Tray 2 Sensor Check RIP Card Cable See “Tray 2 Sensor Test” on page 3-27 . If test fails, replace the sensor. Check the continuity of the RIP card cable. If incorrect, replace the cable. If correct, replace the RIP card.

Power Supply Service Check
Dead Machine
Note: Remove paper from printer prior to performing the dead machine service check. Observe all necessary ESD precautions when removing and handling the RIP card, engine board, or any of the installed option cards or assemblies. FRU 1 AC Outlet Action Check the AC outlet for correct line voltage. If incorrect, inform the customer.

2-64 Service Manual

4085-001
FRU 2 Power Line Cord Action Check the power line cord for damage. Check the continuity of the line cord and replace if necessary. Check the continuity on the power switch. If incorrect, replace the power switch. With the power switch turned on, verify the voltage readings at RIP card connector (J1) and engine board connector (J1). The RIP card voltage at J1-1 and J1-2 should be approximately +5 V dc at each pin. Check the engine board connector (J1) voltage to verify that J1-3 and J1-4 have approximately +35 V and J1-11, J2-12 read 5 volts each. Note: If any of the voltage readings are not correct, replace the power supply.

3 4

Power Switch Power Supply

RIP Card Service Check
FRU 1 Parallel or USB does not work Action Check parallel or USB cables and J2 connection. If OK, check the voltage reading at connector J1 for +5 V dc at pins 1 and 2. If the voltage reading is correct, replace the RIP card. If voltage is not correct, replace the power supply.

Diagnostic Information 2-65

4085-001 Print Quality Service Check Note: Before troubleshooting any print quality problem. or for contamination on the pogo pins. conduct a clean as described on page 3-8. (care should be taken to avoid contact with the pogo pins that contact the ink tank memory chips. Replace if necessary. lint-free cloth. Clean the pogo pins only with a clean. lint-free. However. FRU Action The machine print quality can look poor as a result of either faulty printheads or poor carrier to printhead electrical contact. the problem could be pogo pin to printhead tab circuit contact. Inspect for damage and replace if necessary. damp cloth. If the missing nozzles are patterned. Look for breaks in the diagonal lines that are printed on the page. Generally random missing nozzles indicate a printhead failure. Print the ‘Contacts Page’ in diagnostics to evaluate for electrical interface errors. These pins are lubricated with a grease to minimize wear and prevent pogo pin damage. Gently blot and wipe dry. more patterned print quality defects may be caused by poor carrier to printhead electrical contact or electrical interface problems with the carrier cable. Inspect the carrier for bent pogo pins. Remove the printhead and clean the tab circuit with a clean. 1 Printhead Carrier Assembly Print the 'Contacts Page' in diagnostics. If the missing nozzles are patterned. Check that the carrier cable connections are clean and secure. the problem could be the carrier cable. Set print quality to normal and be sure the correct paper type is selected in the Paper Menu. Note: Unplug the printer before cleaning contacts. or engine card. carrier card. be sure the cartridge is in good condition. This grease should not be smeared on the surrounding pogo pins as it may trap contamination and cause contact failures). 3 Carrier Cable 2-66 Service Manual . Try cleaning the printhead nozzle plate by holding a damp cloth against the nozzle plate for about three seconds. 2 Printheads If the error is random missing nozzles.

then the carrier card. Gears for wear or binds. • Carrier to carrier frame engagement should be lubricated with grease P/N 99A0394. 7 Alignment Characters having uneven or jagged edges. Paper for curl or wrinkles. Paper path for obstructions. Check the following: • • • • • • 6 Transport Correct type of paper is being used. Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. damage. See “Aligning the Printheads” on page 3-5 . or looseness. or uneven vertical. the problem could be the engine board or carrier card. • Carrier guide rod for wear or dirt.4085-001 FRU 4 Engine Board Carrier Card 5 Paper Feed Action If the missing nozzles are patterned. Lubricate the carrier guide rod and carrier frame on both sides where the two surfaces ride on the frame. First try replacing the engine board. Blurred print and voids can be caused by problems in the transport area. • Idler pulley parts for wear. dirt. Check the following: • Transport belt for wear and full engagement into the carrier grip. • Encoder strip for wear or dirt. horizontal. 8 Ink Cartridges Diagnostic Information 2-67 . or looseness. bidirectional (black or color) alignment can be checked by entering Diagnostics Mode and selecting Align Printheads. Check the ink cartridges. Distance between print media and printheads. Feed rollers for wear.

Note: Lubricate the rod and the carrier rod bearing surface. or loose motor pulley. Go to the “Carrier System Test” on page 3-32 . Disconnect the transport motor (J5) from the engine board. If you find a pin shorted to the housing. replace the index/ encoder disk assembly. FRU 1 Transport Motor Action Check the motor for binds. See “Encoder Disk Feed Roller Assembly Removal” on page 4-34 . 2 Index Sensor Transport Service Check Note: If the carrier strikes the left side frame and continues to drive into the frame. To check the sensor. 3 4 Carrier Guide Rod 2-68 Service Manual . Check for motor pins shorted to the motor housing. replace the motor. replace the engine board. Clean the carrier rod. Do not use excess lubricant. Check for approximately 12 ohms between pins 1 and 2 on the motor cable. If the test fails. see the “Index System Test” on page 3-33 . If the failure remains. replace the motor. If the reading is incorrect. Action If the index motor does not work. see the “Maintenance Station Service Checks” on page 2-56 . If incorrect. If the index motor is working correctly see “Index System Test” on page 3-33 . replace the engine board.4085-001 Index Card/Sensor Service Check FRU 1 Index motor does not work. Disconnect (J2) from the engine board and check for approximately +29 V dc between (J2-1) and ground. then see page 2-48. Take care to protect the encoder strip from grease. see “Index Motor Service Check” on page 2-57 . 2 Maintenance Homing Sensor Engine Board If access door switch does not work or carrier does not move.

Action Check for worn. A problem with the maintenance station can cause carrier movement problems at the right margin. Diagnostic Information 2-69 . See the “Carrier System Test” on page 3-32 . Check for obstructions blocking carrier movement. dirt. 7 8 Printhead Cable Maintenance Station Be sure all connectors are fully seated. Check the cables for damage. and grease.4085-001 FRU 5 Carrier Belt Idler Pulley Parts Carrier Frame 6 Encoder Strip Check the encoder strip for wear. See the “Maintenance Station Service Checks” on page 2-56 . loose or broken parts.

User Error Messages Message 30 Cartridges Missing: • Color • Black Explanation Press Go to clear the error. If the reading is incorrect. replace the engine board. disconnect (J8) and check between pins 2 and 4 on the connector for approximately 7. If the voltage is correct. 2. replace the cam system motor.95 between pins 5 and 7. At pins 1. If voltage is incorrect. 3. Note: If a short exists in the cam system motor.9 volts. Supplies status appears on the display and the cartridge missing shows in the supplies menus. replace the engine board. Action Check the voltage at connector (J8) on the engine board. and 4 with the power on.4085-001 Cam System Motor/Sensor Service Check FRU 1 Motor does not work. If the reading is not correct. If continuity exists. 2-70 Service Manual . There should be approximately +34 V dc on each pin to ground. This remains until the user accesses the Tests Menu to install a cartridge and fill the empty slots. check the continuity between pins 2 and 4 to the motor case.5 ohms. damage to the engine board drivers and power supply may occur. disconnect (J8) from the engine board and check for an ohm reading of 6. check connector (J8) at pin 5 for approximately +4. If the voltage is incorrect. If the voltage is correct. replace the sensor. To check the sensor. Bat Wings do not move.

• Simplifying your print job. Menu Lockout does not prevent access to the Busy/Waiting Menu group. The menu buttons are not active when Reset Control is Off. 51 Defective Flash Press Go to clear the message and continue processing the job.4085-001 Message 38 Memory Full Explanation Press Go to clear the message and continue processing the job. The flash is marked as bad and normal operation continues. You must allow additional memory to complete your print job by: • Deleting fonts. All downloaded fonts and macros not written to flash will be deleted. 53 Unformatted Flash Press Go to clear the message. Some data will be lost. and other data in RAM. Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group. Menu Lockout does not prevent access to the Busy/Waiting Menu group. Flash operations will not be allowed until the flash is formatted. Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group. • Installing additional memory. Diagnostic Information 2-71 . The menu buttons are not active when Reset Control is Off. macros.

a parity error has occurred. If bit 15 is on. The menu buttons are not active when Reset Control is Off. a framing error has occurred. If a parallel error has occurred. 2-72 Service Manual . Press Go to clear the message and continue processing the print job. Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group. or the printer is powered off. check the cable connection between the host and printer. baud. reporting of further host interface errors for the associated port is suppressed until the interface parameters are changed. Press and hold Select and then press Return to determine the exact cause of host interface error. an overrun error has occurred. If a serial error has occurred. parity and data bits) are set correctly on the printer and the host computer. or due to a faulty cable. Menu Lockout does not prevent access to the Busy/Waiting Menu group. If bit 14 is on. Once a host interface error has been displayed for the first time.4085-001 Message 54 Parallel Error Explanation An IEEE 1284 protocol error is detected on the parallel host interface. If bit 13 is on. a 16-bit error code displays in hexadecimal on the second line of the LCD. be sure the serial interface parameters (protocol. If a serial error has occurred. The job may not print correctly. Verify that the correct cable is used.

The printer discards any data received on the serial port. Enable the serial port. or the printer is reset. 200 Paper Jam This message indicates that a paper jam has occurred. Diagnostic Information 2-73 . see the “Paper Feed Service Check” on page 2-61 . Note: The menu buttons are not active when Reset Control is Off.4085-001 Message 56 Parallel Port Disabled Explanation Once the error has been displayed for the first time. Press Go to clear the message. If the error does not clear after cleaning the paper jam. reporting of further errors is suppressed until the menus are entered. Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group.

4085-001 2-74 Service Manual .

See “Entering CE Diagnostics Mode” on page 3-2. Diagnostic Aids Printer Operations Operations Initiated by Pressing Buttons at Power-On Reset The table below contains a list of the printer operations that are activated by pressing a sequence of buttons while powering on the printer. See “Entering CE Diagnostics Mode” on page 3-2. Power-On Reset Button Functions Function Enter Configuration Menu Disable/Enable Panel Menus POR Key Sequence Select and Return Reference Section Go and Stop Note: POR key sequence gains entry to Configuration Menu from which setting may be modified. Go and Select Menu> and Select and Go Enter Flash Engine Mode Menu> and Select and Return Diagnostic Aids 3-1 . See “Enter Flash Engine Code Mode” on page 3-3.4085-001 3. See “Clear NVRAM (noncritical sections only)” on page 3-3. Enter CE Diagnostics Mode (Mode 1) Enter CE Diagnostics Mode (Mode 2) Clear NVRAM Go and Return See “Disable/Enable Operator Panel Menus” on page 3-2.

Note: This method of locking/unlocking the Operator Panel Menus may ONLY be used when the PJL PASSWORD Environment Variable is set to zero. To unlock. To indicate the menus are being unlocked. 4. the Panel Menus selection is NOT available in the Configuration Menu Group. the printer instead automatically provides access to the Busy/Waiting Menu group. enable the menus. The printer performs its normal POR cycle and shows the first entry in the Configuration Menu. 3-2 Service Manual . Turn on the printer. the Enabling Menus message is shown. If PASSWORD is set to any non-zero value. Note: These steps do not prevent access to other menu groups. 1. Access to the Busy/Waiting Menu group permits the user to execute operations available in this menu when the printer is not busy. Turn off the printer.4085-001 Disable/Enable Operator Panel Menus To prevent users from accessing the Ready Menu group and modifying default printer settings. If a user attempts to access the Ready Menu Group while the menus are locked. Entering CE Diagnostics Mode Caution: The Customer Support Center should never instruct users how to access Diagnostics Mode. that is. Release the buttons once the Performing Self Test message is displayed. follow these steps: Note: These steps do not prevent access to the Busy Menu group and the Diagnostics Menu group. 2. 3. Select the Panel Menu setting and modify the value to Disable. Press and hold the buttons identified in the “Power-On Reset Button Functions” on page 3-1 to gain access to the Configuration Menu Group. The Disabling Menus message is temporarily shown. repeat the above steps except modify the Panel Menus value to Enable.

Press and hold the buttons identified in “Power-On Reset Button Functions” on page 3-1. Clear NVRAM (non-critical sections only) This operation restores factory default values for most printer settings. Turn off the printer. Typically this function is used to reprogram defective Engine code. 2.To indicate factory defaults are being restored. 3. The restoration of the factory default values occurs after the user exits the Configuration Menu Group. Warning: Extreme caution should be used when using this operation as it cannot be undone. Turn on the printer. Release the buttons once the Performing Self Test message is displayed. Diagnostic Aids 3-3 . and lets you program new code in the Engine card. the Restoring Factory Defaults message is displayed. 1. The Customer Support Center should only instruct customers to use this function as a last resort. Note: This operation can also be initiated from the Configuration Menu Group by selecting the Factory Defaults = Restore All option. Turn on the printer.4085-001 Use the following steps to access the Diagnostics printer settings and operations. Turn off the printer. 3. Press and hold the buttons identified in “Power-On Reset Button Functions” on page 3-1. Release the buttons once the Performing Self Test message is displayed. Use the following steps to restore the factory default values for all affected settings: 1. Enter Flash Engine Code Mode This operation lets you POR the printer into a mode that disables the Engine Code. 2.

Change Printheads Select Change Printhead from the Utilities Menu. The printhead life count is kept on the printhead itself. Change Ink Cartridges When the cover is opened. Open the cover and the carrier moves to the far left and any combination of cartridges can be replaced. the carrier returns to the print position. This can occur if the software keys in the printer and ink cartridge are incompatible. Alternatively. an Attendance Message is shown. (In this position.only the ink cartridges can be replaced. so the reported life level (using NPA or the Menus Page) is automatically updated.4085-001 Use the following steps to enter Flash Engine Code mode: 1. If there is a defective or missing printhead when the cover is open. The ink level is on the ink cartridges. Begin programming the Engine code when the Invalid Engine Code message is displayed. the printheads cannot be removed -. 3. there is a menu item in the Utilities Menu which can be selected to replace an ink cartridge.) When the cover is closed. Release the buttons once the performing self Test message is displayed. Open the cover and the carrier moves to the middle and any combination of printheads can be replaced. Turn off the printer. The user can then replace any combination of ink cartridges. 3-4 Service Manual . so the reported ink level (using NPA or the Menus Page) is automatically updated. the carrier moves to the far left. 4. Select Change Ink Cartridge from the Utilities Menu. as in the case of an OEM printer using Lexmark-branded ink cartridges. Press and hold the buttons identified by the “Power-On Reset Button Functions” on page 3-1. If an unsupported ink cartridges is installed. the carrier automatically moves the printhead change location (without the selection of the menu item). 2. Turn on the printer.

certain customers may want to align printheads to achieve real or perceived optimal print quality. From each section of the alignment page. Following a printhead replacement.User Alignment is for fine tuning. From each section of the alignment page. An alignment page prints. This can occur if the software keys in the printer and printhead are incompatible. Coarse Alignment User Alignment should suffice for aligning the printheads. The purpose of the Coarse Alignment is to get the printheads roughly aligned . However.4085-001 If an unsupported printhead is installed. an Attendance Message is shown. CE personnel and other cases. the user is required to pick a selection that “lines up” the best. the printer automatically initiates an alignment procedure. However. To align the printheads. as in the case of an OEM printer using Lexmark-branded printheads. Aligning the Printheads User Alignment The printheads come from the factory pre-aligned and do not need to be aligned. for manufacturing. select Align Printheads from the Utilities Menu. Select Coarse Alignment from the Configuration Menu. Diagnostic Aids 3-5 . the user is required to pick a selection that “lines up” the best. A coarse alignment page prints. Enter each selection on the operator panel. Enter each selection on the operator panel. Coarse Alignment may be used.

Paper Size If the User Default Paper Source contains letter. 3-6 Service Manual . legal. or A4.4085-001 Alignment Page Fixed Settings (User Alignment and Coarse Alignment) Printer Setting Separator Sheets Orientation Paper Source Value Used for Menus Page None Portrait If the User Default Paper Source contains letter. the alignment page is formatted for letter or A4 based on the value of the US/NonUS printer setting. If not. the alignment page is printed on the User Default Paper Source’s installed size. Paper Type The selected source’s installed paper type. another source is automatically chosen. or A4. Note: The User Default Setting is used for any setting NOT listed in the table. If not. legal. the alignment page is printed from the User Default Paper Source.

selective priming of “bad” printheads. There are two classes of cleaning that can be performed: • Short Clean is a “spit and wipe” cycle followed by a Print Quality • test page. Short Clean should be used first. Long Clean consists of printing a Print Quality test page. and then prompting the user to see if print quality has improved. If print quality has not improved.4085-001 Cleaning Printheads The Clean Printheads operation is used to clean and maintain the printheads. If print quality improves and is acceptable on all printheads. the Ready prompt appears. prompting the user for “bad” printheads. the process repeats. printing the Print Quality test page. This mechanical operation performed by the print engine is recommended when print quality becomes degraded. Long Clean can result in the disposal of a significant amount of ink and as such should be used only when Short Clean does not correct the problem. Diagnostic Aids 3-7 .

to turn tray linking on. Tray 1+2. another source is automatically chosen. For instance. With the tray linking feature turned on. legal. only one set of trays could be linked. some previous Lexmark laser printers let the user set tray linking to one of the following values: Off. If not. As the operation is performed. the alignment page is printed on the User Default Paper Source’s installed size. the feature can be turned on and off by the user. Tray 1+3. or A4.4085-001 Print Quality Test Page Fixed Settings Printer Setting Separator Sheets Orientation Paper Source Value Used for Menus Page None Portrait If the User Default Paper Source contains letter. Cleaning Printheads is displayed. the user had to decide which group of trays should be linked. the alignment page is formatted for letter or A4 based on the value of the US/NonUS printer setting. If not. Tray 1+2+3. Paper Type The selected source’s installed paper type. Linking Input Trays Most network printers offered by Lexmark support an input tray linking feature. Paper Size If the User Default Paper Source contains letter. In general. legal or A4. the alignment page is printed from the User Default Paper Source. the specified trays would be linked if they contained the same media size. Furthermore. In all cases. 3-8 Service Manual .

and custom string.4085-001 Input tray linking description: • Input sources which contain the same paper size. in the following example. and paper type are linked automatically.. Legal. Input sources which support paper (Letter.. so it would not automatically be linked with the other trays. and custom string alike. the input source requested by the print job has priority. However. the MP Feeder does not support PerfectFinish. the user must set the corresponding paper type settings to different values. – MP Feeder (if configured as Cassette and if PerfectFinish has not been requested by the print job) – Tray 1 – Tray 2 Diagnostic Aids 3-9 . In general. The printer only uses this search order when the input source requested by the print job is empty. Tray linking is always active. • Input Source Tray 1 Tray 2 MP Feeder Media Size Letter Letter Letter Media Type Plain Paper Plain Paper Plain Paper Custom String Null Null Null PerfectFinish Capability Yes Yes No • Any combination of trays that support the same media size and • media type can be linked by setting the paper size. type.. which for the traditional Lexmark network printer would mean the trays are all linked. For instance. not envelopes) are linked in the following order.. paper type. custom string. To prevent sources with the same media from being linked. all the trays have the same size. PerfectFinish capability affects the ability of trays to link.

it prints on the page that was inserted. • List of the installed features such as RAM memory SIMMs. The printer automatically exits the control panel menus and prints the menus page. The Printing Menu Settings message appears and the Power indicator blinks while the page formats and prints. Printing Menu Settings Page Select Print Menus from the Utilities Menu. a user may perform an unsolicited manual feed. flash. and their default values. Engine code level. Furthermore. RIP code level. and disk. the RIP and engine assumes that the media that was inserted is the requested size and type that were selected through the data stream. this printer supports manual duplex. Note: Unsolicited manual feed is not available when the MP Feeder is installed. tray code levels. Note: The menus page must be printed on Letter. The engine “grabs” the paper and pulls it into the nip. installed RAM. The menus page contains the following information: • List of all the printer settings in the control panel menus. Printer information such as serial number.4085-001 Unsolicited Manual Feed When configured without a MP Feeder. page count. or A4 paper. Manual Duplex Through the driver. 3-10 Service Manual . the printer continues and prints the back sides from tray 1. a user sticks a piece of paper in the manual slot. Select manual duplex from the driver UI and the printer forces all sheets (front and back sides) to be printed from tray 1 (this eases the confusion related to sequencing of sides). After the driver has sent the front sides of the job. The engine waits for the RIP to submit the print page. a data stream command sent from the driver prompts the user to reinsert the sheets (face up) into tray 1. • optional input trays. Prior to sending a job (or before the first page of the job is picked). Regardless of which source the RIP requests for that page. The MP Feeder functions exactly like the Lexmark Optra™ T MP Feeder. Legal. After pressing Go.

Font ROM Version. in which case the menus page is printed in English. Note: The User Default Setting is used for any setting NOT listed in the preceding table. If not. Note: The menus page is printed in the language specified by the Display Language printer setting. If not. • Miscellaneous supplies information that can be used by the Customer Support Center. • The RIP code level is appended with “:F” or “:R” to indicate whether the board is running code from flash (re programmable) or ROM (not re programmable). legal. Paper Size If the User Default Paper Source contains letter. another source is automatically chosen. unless the Display Language printer setting is Japanese.4085-001 Control Panel code level. Paper Type The selected source’s installed paper type. Diagnostic Aids 3-11 . or A4. and SRAM availability. the menus page is printed on the User Default Paper Source’s installed size. legal. the menus page is formatted for letter or A4 based on the value of the US/NonUS printer setting. This may be useful for product engineers or Customer Support. the menus page is printed from the User Default Paper Source. or A4. Menus Page Fixed Settings Printer Setting Separator Sheets Orientation Paper Source Value Used for Menus Page None Portrait If the User Default Paper Source contains letter.

USB MENU and FAX MENU. The fields are intended to aide the TSC or a CE in diagnosing problems.4085-001 TSC fields on the Print Menus Page The following fields are on the Print Menus page under the “Printer Information” heading. As the operation is performed. Since the printer is capable of storing many pages associated with one or more print jobs from any installed host interface at the time this operation is selected. the Restoring Factory Defaults message is shown.M. 3-12 Service Manual . Y. 1 indicates refilled. Y. and K PH life remaining. and K tanks (0 indicates non-refilled. M. Concatenation of C. Field TS1 TS2 E1 R1 Definition Concatenation of C. SERIAL MENU.Y. M. The following settings in the Ready Menu Group do NOT reset to factory default values: • Display Language (SETUP MENU). and K expiration dates in mmyy format. LOCALTALK MENU. • All settings in the PARALLEL MENU. users need to understand the printer’s algorithm for determining which print job is canceled. Y. NETWORK MENU.) Restoring Factory Defaults The Factory Defaults operation returns most of the operator panel settings in the Ready Menu Group back to their factory settings. INFRARED MENU. and K ink levels. Canceling a Print Job using the Operator Panel The Cancel Job control panel function is used to cancel printing of the current job. Concatenation of C. M. Concatenation of C.

Diagnostic Aids 3-13 • . the waiting state. If the canceled job has ended or has been terminated. After reset processing is complete. many printers use an existing sensor in the printer’s paper path located closest to the selected bin as a trigger for this signal. the busy state. and while many intervention conditions as well as status conditions are displayed. When the Cancel Job operation is selected. and the printer immediately begins processing the next print job. all sheets belonging to the canceled job for which the physical printing process has not yet begun are canceled. However. If the canceled job has neither ended nor been terminated: – A user may stop the canceled job by executing a Front Panel Reset operation. For example. This menu can be accessed while the printer is in the ready (or idle state). Note: The sheet that is currently printing and any other sheets in the path are canceled and ejected. The cancel job operation is in the control panel JOB MENU. the host application should not be instructed to stop sending printer data when a cancel job operation is selected. the printer begins processing the next print job. – If the host computer continues to send data which belongs to the canceled job. the print engine sends a “Print Complete” signal to the printer controller to indicate the associated sheet is complete. many laser printer engines send the “Print Complete” signal when the trailing edge of a sheet crosses the sensor located in the area of the fuser. When a job is canceled: • After the printer identifies which job is canceled. Note: Unlike a operator panel reset. the printer discards the data until the job ends or is stopped.4085-001 When each sheet is printed and the engine has placed the sheet in a printer bin. since most printer bins are not equipped with sensors to detect when a sheet has arrived in a bin. the printer • determines whether the canceled job has ended or has been terminated. the printer identifies the next sheet for which “Print Complete” will be received and cancels the print job associated with the identified sheet. Once the cancellation processing is complete. the printer begins processing the next print job.

However. and the cancel operation is used on a PPDS job which does not contain an end of job command. the printer is deadlocked waiting for an end of job command which will never be sent. Resetting the Printer using the Operator Panel The Reset Printer control panel function is used to reset the active port and restore the printer’s user default settings. 3-14 Service Manual . While the printer is in a state which permits the cancel job operation. When the expiration of the applicable timer occurs. the printer uses the Flushing timer value.4085-001 – If the host computer stops sending data without ending the canceled job. Note: If a user has disabled the Print timeout timer which is used to terminate a PPDS job. The printer automatically exits the control panel menus and performs the job cancel operation. When this situation occurs. if the host computer stops sending data again. the user must explicitly execute a Front Panel Reset to terminate the canceled PPDS job. the procedure to stop the job is repeated. The following screen is displayed.) Invoking Cancel Job 1. the printer’s ability to complete the cancellation operation is suppressed. the canceled job is stopped and the printer begins processing the next print job. In other words. As the job is canceled. (For PCL emulation. JOB MENU Cancel Job 2. (This is not an issue for PCL emulation since the Flushing timer is used to terminate a canceled PCL job. the printer initiates a timer which stops the canceled job.) Note: If the host computer resumes sending data which belongs to a canceled job. then the timer value used to stop the job is reset and the printer resumes looking for a data stream command which indicates the job has ended. press Menu> or Menu<. the Canceling Job message appears. meaning the appropriate timer is restarted from the beginning. Press Select.

the printer is initialized as follows: • A maximum of one page is launched. PJL current environment is restored to the user default environment. – USB . If an interpreter is currently processing data for a page. Other print jobs buffered in the printer may also be fully or partially lost! Note: Before performing a operator panel reset. Fixed default settings are reset to the factory set values. When the printer is reset from the operator panel. Data on only the active port is discarded in the following manner: – Parallel . instruct the host application to stop sending printer data. This menu is available in both the Ready Menu Group and the Busy/ Waiting Menu Group. the data and partially completed page are discarded. Note: The sheet that is currently printing and any other sheets in the path are canceled and ejected.the host computer stops sending data and link data is discarded until data has not been received for a half of a second. Variable default settings for paper sizes become the active default formatting sizes. Diagnostic Aids 3-15 .4085-001 Warning: Use care when invoking this function. all other queued pages • • • • • are discarded.the host computer stops sending data and link data is discarded until data has not been received for a half of a second. The reset printer function is in the operator panel JOB MENU. Note: Some operations are restricted at certain times in the Busy/ Waiting Menu Group.

Press Select.4085-001 Invoking Reset Printer (from the Ready message) 1. 3-16 Service Manual . Since the JOB MENU is the only menu active. The following screen is displayed. As the operation is performed. SUPPLIES MENU 2. Reset Printer is not displayed when Reset Control is set to off. Press Menu> or Menu< to enter the menus. the printer automatically selects it and displays the following screen. Press Menu> or Menu< until JOB MENU is displayed on the second line. JOB MENU Reset Printer 2. Press Menu> or Menu< to enter the menus. the Resetting the Printer message appears. and all other messages) 1. The printer automatically exits the operator panel menus and performs the reset operation. Note: The system administrator can disable the Reset Printer function by turning the Reset Control setting off. JOB MENU Reset Printer 3. Press Select. As the operation is performed. Invoking Reset Printer (from Hex Trace mode. Press Select. The printer automatically exits the operator panel menus and performs the reset operation. The following screen is displayed. the Resetting the Printer message appears.

Fixed default settings are reset to factory set values. the following events occur: • Fixed default settings are set to factory set values. Variable default settings are returned to values stored in NVRAM. Variable default settings for paper sizes become the active default formatting sizes. Downloaded fonts and macros with permanent status are retained. Receiving INIT * causes the parallel interface to go busy.4085-001 Other Resets Power On Reset -. 01 or 03). • Portions of printer memory that store page. and • • • • • • then initialization takes place. Downloaded fonts and macros with temporary status are deleted. The link buffer is left intact. and macro information are cleared. INIT * -. Other resets which cause similar events: • NPA Cold Start (Front Panel. Diagnostic Aids 3-17 . INIT * is not honored while Hex Trace is active. currently active pages are discarded and emulators are reset. The INIT * is processed when the parallel interface becomes active and all preceding characters have been processed. • INA Hard Reset For these resets. font.and similar resets When the printer is turned on.Parallel Interface Initialization The INIT * signal causes the printer to be initialized as follows (unless the INIT * signal is disabled by its variable default setting): • Data received before reception of an INIT * signal is printed.

When an intervention required error condition occurs. 1.4085-001 NPA Response Any reset conditions that cause the loss of resources or a change in emulation requires an NPA response to inform the host computer. but it doesn’t contain a Form Feed command after the last page. NPA responses are only given if NPA bidirectional communication is active in the printer. the link remains active and takes data until the link buffer fills. For all other reset cases. the Waiting message is displayed. When this situation occurs. See separate specifications on NPA implementation. This situation occurs when a PCL 5 emulation or PPDS job is sent to the printer. The following screen is displayed. Loss of Link Data and Link Response An operator panel reset is the only reset condition which causes the loss of link data. The link immediately goes busy on intervention required conditions. Printing Buffer Contents The print buffer operation is used to print any partial page that is waiting to be printed. JOB MENU Reset Printer 2. Press Menu> until the following screen is displayed. follow these steps. To invoke the Print Buffer operation while the Waiting status screen is displayed. JOB MENU Print Buffer 3-18 Service Manual . Press Menu> or Menu< to enter the menus. the error is fed back immediately to the attached host computer.

To activate hex trace mode. the Power indicator should blink and the following screen will be displayed: Registration Page Printing The printer prints the registration page from the requested source. Press Select. No buttons are active while the registration page is printing. then proceed to a menu screen where the registration can be entered. the registration screen is displayed. It is assumed that either Letter or A4 is loaded into the requested source. Once complete.Print Tests Registration Upon selection. the printer automatically exits the operator panel menus. PS 2. While the page is printing. and so on) are printed rather than processed. select Reset Printer from the JOB MENU or turn the printer off. The printer automatically exits the operator panel menus and prints the partial page. Therefore. Diagnostics (Mode 1) . Activating Hex Trace Debug Mode The Hex Trace menu function puts the printer in a mode that is used to isolate print job problems. Each byte of information contained in the job is printed in both hexadecimal and character formats. Note: If the Print Buffer operation is selected while the printer is not in the Waiting state. To exit hex trace mode. Note: The system administrator can disable the Print Buffer function by turning the Print Buffer Control setting Off. select Hex Trace from the UTILITIES MENU. this item will first cause a page to be printed from the requested source. but no page is printed. Print Buffer is not displayed when Print Buffer Control is set to Off. all emulation commands (PCL 5. PJL. as is normally done. Diagnostic Aids 3-19 .4085-001 3.

4085-001 The Registration menu is formatted so that all menu items fit on a single screen as shown. This allows manufacturing to quickly set and verify the registration setting. Tray 1 T= sxx* L= sxx* Terminology:

• T represents Top Margin and L represents Left Margin. • s represents the sign for negative values. This space is blank for
positive values.

• xx represents the margin value. • An asterisk (*) is displayed next to the default value.
Upon first entering the Registration menu, the Left margin sign/value pair flashes. This indicates it is the margin value being changed. To change the value, press either Menu> or Menu<. Once the value you want is displayed, press Select to save the value and move to the next margin value. The margin values are traversed in this order: Top, then Left. If you need to skip a margin value (that is its value is OK), press Select. The default value remains the same. If Return is pressed to exit the Registration menu after a margin value has been incremented or decremented (but not saved via Select), then the default value is not changed. To exit the Registration menu, press Return. Input Source Print Tests The Diagnostic Input Source PRINT TESTS verifies that the printer can print on media from each of the installed input sources. Each of the installed sources is available as a selectable option within the PRINT TESTS menu. For each source, there are two choices:

• Single (print the Print Test page once). • Continuous (continue printing the Print Test page until Return
or Stop is pressed).

3-20 Service Manual

4085-001 The content of the Print Test page varies depending on the media installed in the selected input source. If a source is selected that contains paper (that is, letter, legal, and so on), then a page similar to the Quick Test page is printed. However, it does not contain the Print Registration diamonds. If a source is selected which contains envelopes, then an Envelope Print Test pattern is printed. This pattern only contains text, which consists of continuous prints of each character in the selected symbol set. If Continuous is selected, all sources printing with paper sizes prints the same page continuously until the test is stopped. If Continuous is selected for a source which contains envelopes, then the envelope print test pattern is printed on the first envelope and subsequent envelopes are blank. Note: The Print Test page can be printed on any paper or envelope size. However, more than one sheet of some media sizes may be required. While the page is printing the following message is displayed. The Power indicator also blinks while the page is printing. <Input source> Printing If Single is selected, no buttons are active while the Print Test page is printing. However, if Continuous is selected, Return or Stop can be pressed to cancel the test. While the test is being canceled, the following message is displayed. <Input source> canceling... Note: <input source> represents the input source selected for the Print Test. One of the following sources is displayed: Tray 1, Tray 2, or MP Feeder.

Diagnostic Aids 3-21

4085-001 Contacts Page Print Test This test prints the Contacts Page, which can be used by the Customer Support Center or CE to diagnose problems involving printheads, printhead cables, pogo pins, or electrical interfaces between the printheads and the carrier. Prt Contacts Pg Printing Contacts Page Fixed Settings
Printer Setting Separator Sheets Orientation Paper Source Value Used for Menus Page None Portrait If the User Default Paper Source contains letter, legal, or A4, the alignment page is printed from the User Default Paper Source. If not, another source is automatically chosen. Paper Size If the User Default Paper Source contains letter, legal, or A4, the alignment page is printed on the User Default Paper Source’s installed size. If not, the alignment page is formatted for letter or A4 based on the value of the US/NonUS printer setting. Paper Type The selected source’s installed paper type.

Diagnostics (Mode 2) - Hardware Tests
LCD Hardware Test Select this test to continually execute the LCD display test. To cancel the test, press Return or Stop.

3-22 Service Manual

4085-001 Button Test The Button Test verifies the operation of each button on the operator panel. When Button Test is selected, the following screen is displayed. OP OP OP OP OP OP While a button is pressed, CL (Closed) is displayed. Likewise, while a button is not pressed, OP (Open) is displayed. If the wrong message is displayed, then the button is malfunctioning. To exit the button test, press Return or Stop. The previous menu screen will be displayed when the button is released. DRAM Memory Test The DRAM Memory Test checks the validity of DRAM (both standard and optional DRAM). The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly. When this test is selected from the control panel, the following screen is displayed and the printer begins testing DRAM memory for the first time. DRAM Memory Test P:###### F:##### Terminology:

• P:###### represents the number of times the memory test has •
passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999. F:##### represents the number of times the memory test has failed (finished with errors). Initially 00000 is displayed for #####. The maximum fail count is 99,999.

Diagnostic Aids 3-23

4085-001 The power indicator blinks indicating the memory test is in process. The printer continually runs the same test until canceled from the operator panel (by pressing Return or Stop). Each time the test finishes, the screen is updated with the result. If the test passes, the Pass Count is incremented by 1. However, if the test fails, a failure message is displayed for approximately 3 seconds and the Fail Count is incremented by 1.

• DRAM Error
Once the maximum pass count or fail count is reached, the test is stopped and the final test results are displayed. Press Return or Stop to exit the test. ROM Memory Test The ROM Memory Test checks the validity of the RIP code and fonts. When this test is selected from the operator panel, the following screen is displayed and the printer begins testing ROM memory for the first time. ROM Memory Test P:###### F:##### Terminology:

• P:###### represents the number of times the memory test has •
passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999. F:##### represents the number of times the memory test has failed (finished with errors). Initially 00000 is displayed for #####. The maximum fail count is 99,999.

The power indicator blinks indicating the memory test is in process. The printer continually runs the same test until canceled from the operator panel (by pressing Return or Stop).

3-24 Service Manual

the screen is updated with the result. Initially 00000 is displayed for #####.999. the test is stopped and the final test results are displayed. Disconnect the parallel interface cable. 4. if the test fails. or Parallel 3 Wrap). Select HARDWARE TESTS from the Diagnostics Menu. If the test passes. Parallel 1 Wrap. The maximum pass count is 999. The maximum fail count is 99. The following screen is displayed and the printer begins testing the parallel hardware for the first time. Each parallel signal is tested.999. F:##### represents the number of times the test has failed (finished with errors). 2. However. Select the appropriate Parallel Wrap Test (Parallel Wrap. one of the following failure messages is displayed for approximately 3 seconds and the Fail Count is incremented by 1: • ROM Checksum Error • ROM Burst Read Error Once the maximum pass count or fail count is reached. To perform the wrap test: 1. Diagnostic Aids 3-25 .4085-001 Each time the test finishes. Parallel Wrap P:###### F:##### Terminology: • P:###### represents the number of times the test has passed • (finished successfully). Parallel Wrap Test The Parallel Wrap Test checks the operation of the parallel port hardware using a wrap plug. and install the parallel wrap plug (1319128). 3. Initially 000000 is displayed for ######. Select Parallel Wrap to initiate the Parallel Wrap Test. Press Return or Stop to exit the test. Parallel 2 Wrap. the Pass Count is incremented by 1.

Press Return or Stop to exit the test.4085-001 The power indicator blinks indicating the test is in process. the test is stopped and the final test results are displayed. the screen is updated with the result. However. 3-26 Service Manual . The printer continually runs the same test until canceled from the operator panel (by pressing Return or Stop). • • • • • • • • • • • • • • • • • • • • • • • • Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fall Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fall Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum pass count or fail count is reached. if the test fails. Each time the test finishes. If the test passes. one of the following failure messages is displayed for approximately 3 seconds and the Fail Count is incremented by 1. the Pass Count is incremented by 1.

OP is displayed. When the sensor is closed. • PT or Pass-through refers to the pass-through sensor. The following screen is displayed: Tray 1 PO=OP Terminology: • PO or Paper Out refers to the empty sensor.Input Tray Tests Tray 1 Sensor Test This test determines whether or not the Tray 1 input sensor is working correctly. OP = Empty Tray CL = Not Empty To exit the test. Once this screen is displayed. the sensor is malfunctioning. If the wrong message is displayed. the sensor can be manually actuated. CL is displayed. the sensors can be manually actuated. When the Diagnostic Aids 3-27 . To run the test. Once this screen is displayed. To run the test. CL is displayed. select Tray 2 from the INPUT TRAY TESTS menu. When the sensor is open.4085-001 Diagnostics (Mode 2) . select Tray 1 from the INPUT TRAY TESTS menu. When the sensor is closed. select Return or Stop. The following screen will be displayed: Tray 2 PO=OP PT=CL Terminology: • PO or Paper Out refers to the empty sensor. Tray 2 Sensor Test This test determines whether or not the Tray 2 input sensor is working correctly.

OP is displayed. OP = Empty CL = Not Empty To exit the test. Once this screen is displayed. If the wrong message is displayed. The following screen is displayed: MP Feeder PO=OP Terminology: • PO or Paper Out refers to the empty sensor. select MP Feeder from the INPUT TRAY TESTS menu. To run the test. the sensor is malfunctioning. select Return or Stop. select Return or Stop.4085-001 sensor is open. PO=OP = Empty PO=CL = Not Empty PT=OP = Media Clear PT=CL = Media Present To exit the test. the sensor is malfunctioning. CL is displayed. MP Feeder Sensor Test This test determines whether or not the MP Feeder input sensor is working correctly. OP is displayed. When the sensor is closed. If the wrong message is displayed. the sensor can be manually actuated. 3-28 Service Manual . When the sensor is open.

Supplies Sensors This test is used to determine if a group of sensors related to the supplies are working correctly. C is displayed. O is displayed. Once this screen is displayed. The following screen will be displayed: Supplies Sensors TP=O TF=C Diagnostic Aids 3-29 . To run the test.4085-001 Diagnostics (Mode 2) . the sensor can be manually actuated.Base Sensor Tests Paper Path Sensors This test determines if a group of sensors related to the paper path are working correctly. the sensor is malfunctioning. If the wrong message is displayed. The following screen is displayed: Paper Path TC=C IS=C CO=C Terminology: • TC refers to the PerfectFinish path pass-through sensor. TC or IS=O = Media Clear TC or IS=C = Media Present CO=O = Cover Open CO=C = Cover Closed To exit the test. • IS or Input Sensor refers to the input (grit roll) sensor. select Paper Path Sensors from the BASE SENSOR TESTS menu. When the sensor is closed. select Supplies Sensors from the BASE SENSOR TESTS menu. To run the test. When the sensor is open. select Return or Stop. • CO or Cover Open refers to the cover open sensor.

When the sensor is closed. 3-30 Service Manual . When the sensor is closed. Miscellaneous Sensors This test is used to determine if a group of miscellaneous sensors is working correctly.4085-001 Terminology: • TP refers to the PerfectFinish tank presence sensor. When the sensor is open. select Return or Stop. If the wrong message is displayed. • TF refers to the PerfectFinish fluid level sensor state. The following screen is displayed: Motors Sensors CS=O Terminology: • CS refers to the cam stepper home sensor state. To run the test. Once this screen is displayed. the sensor is malfunctioning. the sensor can be manually actuated. TP=O = Tank Missing TP=C = Tank Present TF=O = Cartridge Full TF=C = Not Full To exit the test. To exit the test. C is displayed. C is displayed. If the wrong message is displayed. select Misc Sensors from the BASE SENSOR TESTS menu. O is displayed. the sensor is malfunctioning. the sensor can be manually actuated. select Return or Stop. When the sensor is open. Once this screen is displayed. O is displayed.

The printheads move to the middle of the frame so that the servicer has unobstructed access to the ink-level sensor. the following screen is displayed for 1 second: Printheads Capped Diagnostic Aids 3-31 . After selecting this. Cap Printheads Selection of this operation initiates a printhead capping.602 First the printheads are uncapped. select Ink Level Sensor Test from the BASE SENSOR TESTS menu. this test will automatically exit. the analog ink-level sensor value begins updating in real time. After selecting this.Subsystem Tests Uncap Printheads Selection of this operation initiates a printhead uncapping. To run the test. Diagnostics (Mode 2) . The servicer can affect this value by waving a magnet in front of the sensor. Once the printheads have been presented. the carrier is homed and the printheads are capped. When the test is ended using the operator panel (Return or Stop). the following screen is displayed for 1 second: Printheads Uncapped After uncapping.4085-001 Ink Level Sensor Test This test determines if the ink level sensor is working correctly. The following screen is displayed: Ink Level Sensor Test Level = .

the strip can be wiped carefully with a deionized. The servicer should move the carrier back and forth at a constant speed to determine if there are any noticeable skips or lags in positional count. However. the servicer should manually move the carrier back to the right frame before exiting the test by selecting Return or Stop. and fingerprints. If there is no problem with the motor drive. the printhheads are uncapped and the carrier attempts an “open-loop” safe move to the middle of the printer without use of any feedback signals from the encoder strip. then the servicer can still drag the carrier out to the middle. then the problem is with the DC motor or motor driver. Typical symptoms include shifting margins on previously printed pages. The following screen is displayed: Carrier System Test Position = 1050 Once the test is initiated. If there is a problem. no further attempts are made to drive the carrier using the motor and the carrier position begins updating real time on the panel. A check should be made to ensure that the strip is clean and is not loose when installed or re-installed. At the completion of testing. 3-32 Service Manual . water moistened lint-free cloth if a replacement strip is unavailable. then the carrier is somewhere out in the middle. The servicer can now move the carrier back and forth over the entire carrier shaft. since the printheads are uncapped. It is preferable to replace the strip if it is contaminated. If there is no motion. this test automatically exits. shaft grease. select Carrier System Test from the SUBSYSTEM TESTS menu. The operator panel displays real time information that corresponds to the relative position of the carrier as it is moved back and forth. This moves the maintenance station to the cap position to cap the printheads. The goal is to first isolate a problem with the motor or drive. Carrier System Test This test determines if the carrier system sensor is working correctly. The encoder strip should be inspected with a light for signs of excessive mist.4085-001 After capping. After the engine has finished the open-loop move attempt. To run the test. A skip or lag in the far left or right regions could indicate a cable connection problem or strip contamination. and not the encoder / feedback system.

The following screen is displayed: Index System Test Position = 823 The index system is run open loop and the real time position count is displayed on the panel. This utilizes the maintenance sled motor. When the test is ended. Diagnostic Aids 3-33 . To run the test. To exit the test. The printheads are uncapped. To exit the test. The following screen is displayed: Maint Sled Test State = O The state of the maintenance sled sensor is indicated by “O” for open or “C” for closed.4085-001 Index System Test This test determines if the index system sensor is working correctly. select Return or Stop. select Index System Test from the SUBSYSTEM TESTS menu. The printheads move to the middle of the frame to give the servicer access to the maintenance homing sensor. The status of the homing sensor now begins updating real time on the panel. select Return or Stop. the carrier is homed and the printheads are capped. The servicer can toggle this status by blocking or unblocking the optical sensor. Maintenance Sled Test This test determines if the maintenance sled sensor system is properly functioning. To run the test. select Maint Sled Test from the SUBSYSTEMS TESTS menu.

the sequence of events is the same: 1. Printhead Memories This test determines the status of the electrical connection to the printhead memories. Ink Tank Memories This test determines the status of the electrical connection to the ink tank memories. The status is indicated real time by either “+” (good) or “-” (bad). The following screen is displayed: Printhead Mem Test K=+ CMY=+ To exit the test. The status is indicated real time by either “+” (good) or “-” (bad). the carrier is homed and the printheads are capped. The following screen is displayed: Ink Tank Mem Test K=+ C=+ M=+ Y=+ To exit the test. 3-34 Service Manual . 3. select Return or Stop.Supplies Tests For each of the following four tests. The data corresponding to the test being run begins updating real time on the panel as described. select Return or Stop. 2. The printheads moves to the middle of the frame to give the servicer access to the printheads and tanks under test.4085-001 Diagnostics (Mode 2) . When the test is ended by pressing Return or Stop. The printheads are uncapped when the test is invoked.

select Return or Stop.Printer Setup Setting the Page Count The printer’s page count can be changed using the Diagnostics menus. The resistance is displayed real time. replace the printhead. When Page Count is selected from the PRINTER SETUP menu. The following screen is displayed: K & C TSR Test K=104B3 C=104A1 To exit the test. Note: If zero is displayed on “K”= or “C”=. the current page count is displayed as follows: Page Count =1234567* Diagnostic Aids 3-35 . The engine card contains the printer’s NVRAM memory. The resistance is displayed real time. The following screen is displayed: M & Y TSR Test K=104B3 C=104A1 To exit the test. select Return or Stop. Diagnostics (Mode 2) . Note: If zero is displayed on “K”= or “C”=.4085-001 K&C TSR Test This test determines the status of the printhead TSR (thermal sense resistor). This menu is used by the CE to reset the Page Count setting whenever the engine card is replaced. replace the printhead. M&Y TSR Test This to determines the status of the printhead TSR (thermal sense resistor).

the user may select “Maint Cnt Value. the following screen is displayed. Maint Cnt Value =1234567* 3-36 Service Manual . To change the value. the count may be reset back to zero which indicates a service person performed scheduled maintenance on the printer. the new page count is stored in NVRAM. pressing Return causes the printer to return to the previous menu. When Permanent Page Count is selected.” When the current maintenance counter value is displayed. The counter is used to track printer usage. Viewing the Permanent Page Count The permanent page count setting cannot be modified using the operator panel.000. Perm Page Count =1234567* Viewing and Resetting the Maintenance Page Count The maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. Press Select to move to the next digit. indicating it is the first digit to be changed. The maintenance page count cannot be specifically set using the operator panel. When Select is pressed after the final digit (‘7’ in this example). and keep its current value).4085-001 The left-most digit (‘1’ in this example) blinks. The following screen illustrates the current maintenance counter value. a maintenance intervention and a status indicator appears on the panel. Continue modifying each digit using this method. The next digit (‘2’ in this example) blinks. It can only be viewed using the Diagnostics menus. However. press either Menu> or Menu< until the value you want is displayed. If a user wants to view the current value of the maintenance page counter. All other operator panel keys are ignored. press Select. When the counter reaches 250. To skip a digit (that is.

The printer stores identical errors in consecutive positions in the log.Error Log Viewing the Error Log The Error Log aids the Customer Engineer by providing a history of printer errors. Reset Maint Cnt SAVED When the reset operation is complete. Empty log entries are identified with an error number of 000.” Pressing Select causes the maintenance page counter to be reset back to zero. The following screen is displayed momentarily to indicate the counter is changing. For example. select the Display Log operation from the Diagnostics ERROR LOG menu. Therefore.4085-001 To reset the maintenance page counter. If an error occurs after the log is full. The entire error log cannot be displayed on a single screen. Occupied log entries contain the error number for the message that is displayed on the operator panel. To move Diagnostic Aids 3-37 . then the oldest error is displayed in the position before the empty log entries begin. The most recent error is displayed in position 1. the user selects “Reset Maint Cnt. It contains the 12 most recent errors. If fewer than 12 errors have occurred. Four error log entries are displayed per screen. the printer returns to the “PRINTER SETUP Reset Maint Cnt” screen. In other words. error log position N and position N+1 could contain the same error code if the same error occurs twice in a row. • All 2xx paper jam messages • All 9xx service messages To view the error log. the entire error log takes up 3 screens. 925 is contained in the log when a 925 Service Error occurs. and the oldest error is displayed in position 12 (assuming 12 or more errors have occurred). the oldest error in the log is discarded to make room for the new error. Diagnostics (Mode 2) . The following error messages are stored in the error log.

select the Clear Log operation from the ERROR LOG menu. press Menu<. Clearing the Error Log To clear the error log.4085-001 forward in the log. press Return or Stop. Pressing Return or Stop also exits the Clear Log menu. press Menu>. The following message is displayed. To move backward in the log. 3-38 Service Manual . The error log is cleared and the empty log is displayed: 1-000 2-000 3-000 4-000 Select No to exit the Clear Log menu. Here is an example of the error log screens: 1-200 2-920 3-928 4-922 5-250 6-990 7-230 8-230 9-953 10-000 11-000 12-000 To exit the error log. Clear Log =Yes Select Yes to confirm that you really want to clear the log.

SETUP MENU. then the menu displayed is the last menu in the first menu in the associated group. List of menus in the Ready Menu Group: SUPPLIES MENU. PCL EMUL MENU. so the first menu in the list is displayed as shown. COLOR MENU. Menu List Display PAPER MENU Initially the user is presented with the list of available menus. USB MENU. • SUPPLIES MENU . In addition. Understanding the Menu Display and Menu Buttons The printer settings and operations that are accessible using the operator panel are organized into a list of menus. PAPER MENU. Diagnostic Aids 3-39 . See “Using the Operator Panel” on page 1-4 for an illustration of the operator panel and a description of the buttons and indicator lights. FINISHING MENU. and so on.Printer settings that relate to paper handling.Printer settings that relate to the supplies. press Exit Diagnostics. If the Menu> button is pressed to gain access into a menu group. • COLOR MENU . UTILITIES MENU. Menus This section describes the printer settings and operations that are accessible using the operator panel. it describes the format of the display and the operation of the buttons while the menus are active. • PAPER MENU . Only one menu can be displayed at a time. PARALLEL MENU.4085-001 Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode. The contents of each menu relate to a common subject.Printer settings that relate to color.

The buttons act as follows while the PAPER MENU screen is displayed: • Menu> displays the next menu in the list. 3-40 Service Manual . Select chooses the PAPER MENU.4085-001 The buttons always act on the information displayed on the second line of the display. line 1 is blank). • Printer Setting Display PAPER MENU Paper Source After a specific menu is selected (PAPER MENU in this example). For these menus another menu could be displayed instead of a printer setting. • Menu< displays the previous menu or printer setting in the menu. Since there is no previous level in this case (that is. pressing this button exits the menus and returns the printer to its previous state. • Return returns to the previous menu level displayed on line 1. the display changes as shown. Select chooses the menu or printer setting.) The buttons always act on the information displayed on the second line of the display. The display changes as shown. the menu name is displayed on line 1 and the first printer setting in the menu is displayed on line 2. • Menu< displays the previous menu in the list. • The display changes as shown in “Menu List Display” on page 3-39. printer settings are grouped together into another menu. (In some menus. • Return returns to the previous menu level displayed on line 1. The buttons act as follows while the screen is displayed: • Menu> displays the next menu or printer setting in the menu. For this example.

The buttons always act on the information displayed on the second line of the display. An asterisk is displayed next to the currently selected or default value. The buttons act as follows while the screen is displayed: • Menu> displays the next value in the printer setting’s value list. An equal sign indicates it is assigned to the printer setting. • Return returns to the previous menu level displayed on line 1. the active printer setting is displayed on the first line and the default value (Tray 1) is displayed on the second line. Diagnostic Aids 3-41 . The Saved message is displayed momentarily on the second line. • Menu< displays the previous value in the printer setting’s value list. and then the printer returns to the previous menu level as shown in “Printer Setting Display” on page 3-40.4085-001 Printer Setting Value List Display Paper Source =Tray 1* After a specific printer setting is selected (Paper Source in this example). Select saves the new value currently displayed for the printer setting. • For this example. the display changes as defined in “Printer Setting Display” on page 3-40.

An asterisk is always displayed next to the default or currently selected value.4085-001 Example of Modifying a Printer Setting Using the Operator Panel Use the following to modify any printer setting or initiate any operation in the Busy/Waiting Menu Group. Press Menu> when the Ready message is displayed to access the Ready Menu Group. COLOR MENU Print Quality 3. then press Menu> or Menu< repeatedly until the menu which contains the printer setting you want to change is displayed on the second line. SUPPLIES MENU 2. COLOR MENU is displayed on line 1. and the first entry in the menu is the Font Source printer setting and it is displayed on line 2. An equal 3-42 Service Manual . Press Select to display the default value for that printer setting. Ready Menu Group. The printer is offline and the first menu (SUPPLIES MENU) is displayed on the second line. Press Menu> or Menu< repeatedly until the printer setting that you want to change is displayed on the second line. Press Menu> or Menu< repeatedly until the menu you want to access is displayed on the second line. or Diagnostic Menu Group. Press Select to display the first setting or menu contained in that menu. (If the printer setting you want to modify is in another menu. and the default value (Normal) is displayed on line 2. and press Select to enter the menu. To change the PCL Orientation setting in the Ready Menu Group: 1. The only variation is the action required to access the Diagnostics Menu Group (see “Entering CE Diagnostics Mode” on page 3-2 for details). Note: The Print Quality printer setting is displayed on line 1.

indicating a new default value has been saved into NVRAM. Press Menu> or Menu< repeatedly until the value that you want to select is displayed on the second line. Exit the menus and continue processing print jobs. 6. then press Select.4085-001 sign precedes each value. (Printer settings with a numeric value list let you scroll through the setting’s value list by pressing and holding Menu> or Menu<. Print Quality =Normal* 4. This message is displayed momentarily. COLOR Diagnostic Aids 3-43 . repeatedly press Return until you reach the menu list level. Repeat the preceding steps to find and modify the next printer setting.) Note: A ‘Saved’ message is displayed on line 2. COLOR Print Quality 5. To change a printer setting in another menu. then press Go. indicating the entry on line 1 is a printer setting and it can be assigned to the value on line 2. and then the setting just changed is displayed again.

Ready Menu Group The Ready menu group contains the settings and operations that are accessible when the printer is idle (that is. Note: The Ready menu group is not accessible if Menu Lockout is turned on. To access this menu group. waiting for additional data. or has posted a particular message which allows access to this menu group. See “Ready Menu Group” on page 3-48 for a description of the settings and operations contained in the Ready menu group. See “Busy/ Waiting Menu Group” on page 3-45 for a description of the operations contained in the Busy/Waiting menu group. To access this menu group. or actually printing a job. press Menu> or Menu< while the printer is busy processing a job. press the Menu> or Menu< button while the printer is idle. or printed). Menu Groups Busy/Waiting Menu Group The Busy/Waiting menu group contains the operations that are accessible when the printer is receiving or processing data. One or more operations in this menu group may also be accessible with some error conditions or with certain status messages. processed. waiting for additional data. no jobs being received. Instead. access is automatically granted to the Busy/Waiting menu group.4085-001 Operator Panel Menu Definition The operator panel settings and operations are divided into 4 menus groups. 3-44 Service Manual . which are described in the following table.

For additional information. and operations which are infrequently required by a user. see “Configuration Menu Group” on page 3-60. Generally. See “Entering CE Diagnostics Mode” on page 3-2 for a description of how to enter the Diagnostics menus. settings. the options made available in this menu group are used to configure a printer for operation. Diagnostic Menu Group Note: The Diagnostics Menu group should not be documented in any end-user documentation. The Diagnostic menu group contains the settings and operations used while manufacturing and servicing the printer. See “SUPPLIES MENU” on page 3-48. Busy/Waiting Menu Group The Busy/Waiting Menu group contains two menus: JOB MENU and SUPPLIES MENU.4085-001 Configuration Menu Group The Configuration menu group contains a set of menus. Diagnostic Aids 3-45 . JOB MENU The following table shows the menus in the Busy/Waiting Menu group. See “Diagnostics Menu Group (Mode 1: Printing)” on page 3-62 for a description of the settings and operations contained in the Diagnostic menu group. Top-Level Menu JOB MENU SUPPLIES MENU Intermediate Menus or Menu Items See “Job Menu” on page 3-46 for a list of the menu items. for a list of the menu items. Use the Select and Return POR key sequence to access this menu. Press Menu> from the BUSY screen and the following screen is displayed.

it checks the printer default value). Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Cancel Control is ON. (If a job is active. Press Select to initiate the cancel print job function. Otherwise. For additional information. 3-46 Service Manual .4085-001 Job Menu Job Menu Operations Cancel Job Operation Value or Description No selection exists for this operation. then the printer checks the value selected by the job. This operation is not available in the JOB MENU when the menu is accessed through the Ready Menu Group. see“Canceling a Print Job using the Operator Panel” on page 3-12.

then the printer checks the value selected by the job. see “Ready Menu Group” on page 3-48. Diagnostic Aids 3-47 . see “Printing Buffer Contents” on page 3-18. No selection exists for this operation. it checks the printer default value). Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Reset Control is On. For additional information regarding the Ready Menu Group. Print Buffer Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Print Buffer Control is On and if the printer is waiting for additional data from the host computer. Otherwise. This operation is not available in the JOB Menu when the menu is accessed through the Ready Menu Group. For additional information.4085-001 Job Menu Operations Reset Printer Operation Value or Description No selection exists for this operation. Otherwise. Press Select to initiate printing the contents of the printer’s buffer. it checks the printer default value). see “Resetting the Printer using the Operator Panel” on page 3-14. (If a job is active. This operation is always displayed in the JOB MENU when the menu is accessed through the Ready Menu Group. (The printer checks the value selected by the job. Press Select to initiate the reset function. For additional information.

if Cancel Control is set to off. and assuming the printer is not “Waiting”. See “COLOR MENU” on page 3-50 for a list of the menus or settings. if the printer is “Waiting” and Cancel Control is set to off. the Menus Disabled message is shown. and Print Buffer Control is set to off. 3-48 Service Manual . To provide the user with some feedback. The names of the top-level menus are capitalized and end with “MENU. and the key press used to gain entry into the JOB MENU is ignored. They are displayed on the operator panel in the order shown.4085-001 If no function is available in the JOB MENU at the time the JOB MENU is accessed. then the JOB MENU is not available for selection except via the Ready Menu Group. and no optional bins are installed. Top-Level Menu SUPPLIES MENU COLOR MENU PAPER MENU FINISHING MENU UTILITIES MENU Intermediate Menu. SUPPLIES MENU The SUPPLIES MENU in the Busy/Waiting Menu group is identical to the SUPPLIES MENU in the Ready Menu group. or Operation See “SUPPLIES MENU” on page 3-49 for a list of the menus or settings. Furthermore. and Reset Control is set to off. See “FINISHING MENU” on page 3-51 for a list of the menus or settings. Setting. and Reset Control is set to off. For example.” Whereas. Ready Menu Group The Ready Menu group contains multiple menus. and no optional output bins are installed. See “PAPER MENU” on page 3-51 for a list of the menus or settings. then the JOB MENU is not available for selection except using the Ready Menu Group. See “UTILITIES MENU” on page 3-52 for a list of the operations. the printer prohibits entry into the JOB MENU. the names of the intermediate menus (for example. SERIAL OPTION 1) are just capitalized.

See “SETUP MENU” on page 3-54 for a list of the menus or settings. Intermediate Menu or Setting Black Cartridge Value =Low =Refilled =Life Warning Cyan Cartridge =Low =Refilled =Life Warning Magenta Cartridge =Low =Refilled =Life Warning Diagnostic Aids 3-49 . SUPPLIES MENU The Supplies Menu updates as changes occur even if you are viewing it.The list is only status for the items which are near or past replacement. or Operation See “JOB MENU” on page 3-54 for a list of the operations. See “PCL EMUL MENU” on page 3-56 for a list of the menus or settings. USB MENU See “USB MENU” on page 3-59 for a list of the menus or settings. See “PARALLEL MENU” on page 3-58 for a list of the menus or settings.4085-001 Top-Level Menu JOB MENU SETUP MENU PCL EMUL MENU PARALLEL MENU Intermediate Menu. Setting.

Intermediate Menu or Setting Print Quality Value =Ink Saver =Normal* =Best 3-50 Service Manual . The factory default setting for each item is indicated with an asterisk.4085-001 Intermediate Menu or Setting Yellow Cartridge Value =Low =Refilled =Life Warning Black Printhead Color Printhead PerfectFinish Tray 1 Tray 2 =Life Warning =Life Warning =Empty =Empty =Empty COLOR MENU The following table lists the settings in the COLOR MENU and their corresponding value choices.

then the setting is changed to Tray 1. The factory default value for each setting is indicated with an asterisk.4085-001 PAPER MENU The following table lists the menus and settings in the PAPER MENU. and their corresponding values. or Staple Prime Source is set to MP Feeder when Configure MP is changed to Manual or First. Intermediate Menu or Setting Blank Pages Value =Do Not Print* =Print Diagnostic Aids 3-51 . The factory default value for each setting is indicated with an asterisk. Intermediate Menu or Setting Paper Source Value =Tray 1* =Tray 2 =MP Feeder =Manual Paper =Manual Env If the Paper Source. and their corresponding values. Separator Source. FINISHING MENU The following table lists the menus and settings in the FINISHING MENU.

3-52 Service Manual . see “Printer Operations” on page 3-1.4085-001 Intermediate Menu or Setting Separator Sheets Value =None* =Between Jobs =Between Pages Separator Source Note: Only installed paper sources are displayed. =Tray 1* =Tray 2 =MP Feeder UTILITIES MENU The following table lists the operations in the TESTS MENU. MP Feeder is only displayed when Configure MP is set to Cassette. For a detailed description of each operation.

. No selections exist for this operation.15 (8*) Clean Printheads See “Cleaning Printheads” on page 3-7. Diagnostic Aids 3-53 . See “Aligning the Printheads” on page 3-5...4085-001 Operation Print Menus Value No selections exist for this operation.. See “Printing Menu Settings Page” on page 3-10.. the user enters alignment values for each of the sections of the alignment page. Press Select to initiate this operation.9 (5*) • F Alignment • G Alignment =1. = Short Clean = Long Clean Change Ink Cartridges Change Printheads See “Change Ink Cartridges” on page 3-4.15 (8*) • D Alignment • E Alignment =1. Align Printheads • A Alignment • B Alignment • C Alignment =1. After the alignment page is printed. See “Change Printheads” on page 3-4.. Press Select to initiate this operation.

see “Job Menu” on page 3-46.4085-001 Operation Factory Defaults Value See “Restoring Factory Defaults” on page 3-12.255 (90*) Auto Continue =Disabled* =5... JOB MENU The following table lists the operations in the JOB MENU. The factory default value for each setting is indicated by an asterisk. See “Activating Hex Trace Debug Mode” on page 3-19. =Restore =Do Not Restore Hex Trace No selections exist for this operation... Press Select to initiate this operation. Operation Reset Printer Value Printer For information regarding this operation. SETUP MENU The following table lists the menus and printer settings in the SETUP MENU. and their corresponding values.255 3-54 Service Manual . Setting or Operation Print timeout Value =Disabled =1.

=English =French =German =Italian =Spanish =Danish =Norwegian =Dutch =Swedish =Portuguese =Finnish =Japanese Alarm Control =Off =Single* =Continuous Diagnostic Aids 3-55 .4085-001 Setting or Operation Display Language Value Default set by country Note: Languages in this value list are only displayed if the printer’s operator panel ROM supports the required encoding for the specific language.

3-56 Service Manual . Point Size. Note: Saving Font Source. or Symbol Set has the affect of saving the selected font as the default. Font Name. and their corresponding values. Symbol Set =list of symbol sets available for the default font (US=PC-8* / NonUS=PC-850*) Note: See “Symbol Set Display Format” on page 3-58 for details on the Symbol Set display format. Pitch. or Symbol Set has the affect of saving the selected font as the default. Note: Saving Font Source. Intermediate Menu or Setting Font Name Value =list of available font names for the default font source (R0 Courier*) Note: See “Font Name Display Format” on page 3-57 for details on the Font Name display format.4085-001 Setting or Operation Ink Low Alarm Value =Off =Single* =Continuous Dry Time Delay =Disabled* =Auto =3. The factory default value for each setting is indicated by an asterisk..30 PCL EMUL MENU The following table lists the menus and settings in the PCL EMUL MENU. Pitch.. Point Size. Font Name.

. An asterisk is displayed after the factory default font name. and K for disk). =S##### ThisIsTheFontName* An equal sign precedes the font name. S represents the font source abbreviation (R for resident. If the font name is too long to fit on the display. ##### represents the font ID. The maximum length is five digits. 255 (US=60* / NonUS=64*) =Off* =On Auto LF after CR =Off* =On Font Name Display Format The font names are shown on both lines of the operator panel using the following format. signifying the value list level of the menus.4085-001 Intermediate Menu or Setting Orientation Value =Portrait* =Landscape Lines per Page Auto CR after LF =1.. Diagnostic Aids 3-57 . then it is truncated. F for flash. ThisIsTheFontName represents the font name from the font data. D for download.

4085-001 Symbol Set Display Format The symbol sets are shown on both lines of the operator panel using the following format. Setting NPA Mode a Value =On =Off =Auto* Parallel Buffer a =Disabled =Auto* =3 K . SSID represents the symbol set ID (that is.. signifying the value list level of the menus. (max size allowed) Advanced Status =Off =On* Protocol =Standard =Fastbytes* Honor Init =Off* =On 3-58 Service Manual . The factory default value for each setting is indicated by an asterisk. PARALLEL MENU The following table lists the menu and settings in the parallel port menus and their corresponding values. =SSID ThisIsSymbolSetName An equal sign precedes the symbol set ID. 8U for Roman-8 symbol set)..

4085-001 Setting Parallel Mode 1 Value =Off* =On Note: Only displayed when the associated Parallel Port supports this feature. Parallel Buffer. USB MENU The following table lists the menus and printer settings contained in the USB port menus and their corresponding values. a Whenever the value of NPA Mode. or Job Buffering is changed from the operator panel. or Job Buffering is changed from the operator panel. the printer will automatically reboot upon exiting the menus in order to reconfigure memory. Diagnostic Aids 3-59 . Operation NPA Mode a Value =On =Off =Auto* USB Buffer a =Disabled =Auto* =3K . USB Buffer. the printer automatically restarts upon exiting the menus to reconfigure memory. Parallel Mode 2 =Off =On* Note: Only displayed when the associated Parallel Port supports this feature. The factory default value for each printer setting is indicated by an asterisk... (max size allowed) a Whenever the value of NPA Mode.

For additional information regarding these sequences. Each option is displayed on the operator panel in the order shown. Factory Defaults =Restore All For additional information regarding this operation see “Clear NVRAM (noncritical sections only)” on page 3-3. Intermediate Menu. see “Printer Operations” on page 3-1. see “Printer Operations” on page 3-1. For additional information. settings and operations which are infrequently required by a user. Access to the Configuration Menu Group is gained by using a POR key sequence. follow the reference contained in the following table.4085-001 Configuration Menu Group The Configuration Menu group contains a set of menus. For a detailed description of each operation. Note: Access is gained into the Configuration Menu Group using Select and Return POR key sequence. Value =Disable =Enable* For additional information regarding modification of this printer setting. Note: While the Configuration Menu Group is active. the CONFIG MENU is shown as a top level menu on the first line of the display. see “Disable/Enable Operator Panel Menus” on page 3-2. Setting or Operation Panel Menus Only displayed when the PJL PASSWORD Environment variable is set to zero. the options made available in this menu group are used to configure a printer for operation. 3-60 Service Manual . all host interfaces are offline. Generally. To indicate that the Configuration Menu Group is currently active. The names of the top-level menus are capitalized.

15 (8*) -E =1. the user enters alignment values for each of the sections of the alignment page.27 (13*) Enable PHCE Mode =Disable* =Enable Exit Config Menu No selections exist for this operation. Press Select to initiate this operation. -D =1... Press Select to exit the CON-FIG MENU and restart the printer.. See “Aligning the Printheads” on page 3-5.4085-001 Intermediate Menu. Diagnostic Aids 3-61 . After the alignment page is printed. Setting or Operation Coarse Alignment Value No selections exist for this operation..

The names of the top-level menus are capitalized.20 (0 3-62 Service Manual . or Operation Value The following printer settings are in the REGISTRATION menu. Note: Access is gained into the Diagnostics Menu Group (Mode 1) using the Go and Return POR key sequence. follow the reference contained in the following table.4085-001 Diagnostics Menu Group (Mode 1: Printing) The Diagnostics Menu group contains multiple menus. For a detailed description of each Diagnostic test.20 (0) =20. all host interfaces are offline. • MP Feeder Note: Only displayed if the printer is configured with a Multi-Purpose Feeder Top Margin Left Margin =20. However. see “Printer Operations” on page 3-1. Top-Level Menu REGISTRATION Intermediate Menu. Setting. For additional information. Note: While the Diagnostic Menu Group is active.. they are not displayed as shown... They are displayed on the operator panel in the order shown.. See “Registration” on page 3-19 for a description of how the settings are displayed • Tray1 • Tray 2 Note: Only displayed if Tray 2 is installed.

Diagnostic Aids 3-63 . EXIT DIAGNOSTICS See “Exiting Diagnostics Mode” on page 3-39. Diagnostics Menu Group (Mode 2: Non-printing) The Diagnostics Menu group contains multiple menus. For additional information. follow the reference in the following table. MP Feeder Note: Only displayed if the printer is configured with a MultiPurpose Feeder Prt Contacts Pg =Single =Continuous =Single =Continuous See “Contacts Page Print Test” on page 3-22. The names of the top-level menus are capitalized.4085-001 Intermediate Menu. Note: Access the Diagnostics Menu Group (Mode 2) using the Go and Select POR key sequence. For a detailed description of each Diagnostic test. They will be displayed on the operator panel in the order shown. or Operation Top-Level Menu PRINT TESTS Value Tray 1 =Single =Continuous Tray 2 Only displayed if Tray 2 is installed. see “Printer Operations” on page 3-1. Setting.

See “Button Test” on page 3-23. See “ROM Memory Test” on page 3-24. 3-64 Service Manual . all host interfaces are offline. See “Parallel Wrap Test” on page 3-25. Setting. See “LCD Hardware Test” on page 3-22. Top-Level Menu INPUT TRAY TESTS Intermediate Menu. See “Miscellaneous Sensors” on page 3-30. See “Ink Level Sensor Test” on page 3-31.4085-001 Note: While the Diagnostic Menu Group is active. See “MP Feeder Sensor Test” on page 3-28. See “Paper Path Sensors” on page 3-29. or Operation Value Tray 1 Tray 2 MP Feeder HARDWARE TESTS LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap BASE SENSOR TESTS Paper Path Sensors Supplies Sensors Miscellaneous Sensors Ink Level Test See “Tray 1 Sensor Test” on page 3-27. See “Supplies Sensors” on page 3-29. See “DRAM Memory Test” on page 3-23. See “Tray 2 Sensor Test” on page 3-27.

or Operation Top-Level Menu SUBSYSTEM TESTS Value Uncap Printheads Cap Printheads Carrier System Test Index System Test Maintenance Sled Test SUPPLIES TESTS Ink Tank Memories See “Uncap Printheads” on page 3-31. See “Maintenance Sled Test” on page 3-33. See “K&C TSR Test” on page 3-35. Setting. See “Cap Printheads” on page 3-31. See “Index System Test” on page 3-33. Page Count Perm Page Count Serial Number =0 to 9999999 (0) =0 to 9999999 (0) =xxxxxxxx (printer serial number) where x = A-Z or 0-9 =-4 to 6 (0) Par S Strobe Adj Diagnostic Aids 3-65 . See “M&Y TSR Test” on page 3-35.4085-001 Intermediate Menu. See “Printhead Memories” on page 3-34. Printhead Memories K&C TSR M&Y TSR PRINTER SETUP Defaults =U. See “Carrier System Test” on page 3-32. See “Ink Tank Memories” on page 3-34.S.S.* =Non-U.

3-66 Service Manual .4085-001 Intermediate Menu. =Yes =No EXIT DIAGNOSTICS See “Exiting Diagnostics Mode” on page 3-39. See “Clearing the Error Log” on page 3-38. or Operation Top-Level Menu ERROR LOG Value Display Log Clear Log See “Viewing the Error Log” on page 3-37. Setting.

Connect the wrist band to the engine ground point. do not touch its pins. Repair Information 4-1 . Printer covers and metal tables are electrical grounds. Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers. and furniture. If you are removing a pluggable module. if you need to put down the ESD-sensitive part for any reason. Do not place the ESD-sensitive part on the printer cover or on a metal table. To prevent damage to ESD-sensitive parts. CAUTION: Read the following before handling electronic parts. Be careful in working with ESD-sensitive parts when cold weather heating is used because low humidity increases static electricity. keep all ESD-sensitive parts in a grounded metal cabinet (case). carpets. High voltage is present in the power supply as long as it is plugged into the electrical outlet. This discharges any static electricity in your body to the printer.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install printer covers when you are not working on the printer. and do not put unprotected ESD-sensitive parts on a table. When working on the printer. Hold the ESD-sensitive part by its edge connector shroud (cover). Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. use the correct tool. always unplug the printer from the electrical outlet. If possible. Put the ESD wrist strap on your wrist. such as turning off power before removing logic boards: • • • • • • • • • Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to install the part into the printer. follow the instructions below in addition to all the usual precautions.4085-001 4. first put it into its special bag. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.

4-2 Service Manual . in the Printer Control program. press the hook end of the latch away from the part to which it is latched. Releasing Plastic Latches Many of the parts are held in place with plastic latches. The latches break easily. To remove such parts.4085-001 Adjustments The user is directed. to perform the printhead to printhead and bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. release them carefully. CAUTION: Unplug the power cord before removing any parts.

Open the rear door. Remove two clips and remove the top door. 4. 3. 6. Remove the four screws {A}. 2. Remove Multi-Purpose Feeder.4085-001 Rear Cover Removal 1. 5. Repair Information 4-3 . Depress the four latches {B}. Remove the rear cover.

4085-001 4-4 Service Manual .

3. Remove the four screws located on the rear operator panel housing. 5. 4. Remove the rear cover. Repair Information 4-5 . Remove the operator panel. 2. 3. Remove the screw {A}. 2. Note: Use care not to damage the bat wings. Lift the front of the exit tray and pull forward to remove. Exit Tray Removal 1. Depress the latch on the bottom of the tray. Lift the cover and unplug the operator panel from the engine board. Remove the paper tray.4085-001 Operator Panel Cover/Operator Panel Removal 1.

The restraint screw does not have to be removed. Remove the cover. Open the top door. 3. 2. 4-6 Service Manual . The restraint has a T-end which can be twisted and removed. twist the end of the strap that is in the machine and remove. Remove the two screw {A} from the left frame cover. Partially close the top cover.4085-001 Left Frame Cover Removal 1. 4.

Move carrier to the right. 5. Remove the exit tray cover. Cover guides are located on the bottom edge of the cover. 1. 3. Remove the screw {A} from the left side of the carrier frame.4085-001 Left Cover Removal Remove the rear cover. Remove the cover. Repair Information 4-7 . 2. reinsert cover guides before installing the screws. Remove the two screws {B} from the left front side of the paper tray frame. Note: When reinstalling. 6. 4.

4085-001 4-8 Service Manual .

4. Repair Information 4-9 . Note: When reinstalling. Note the wire routing. Remove the rear cover. 7. 8. Remove the exit tray.4085-001 Right Cover/Power Switch Removal 1. Move the carrier to the left. Refer to “Rear Cover Removal” on page 4-3. Cover guides are located on the bottom edge of the cover. Remove the cover. 2. 3. reinsert the cover guides before installing the screws. Remove the operator panel cover. Refer to “Exit Tray Removal” on page 4-5. 6. Remove two screws {A} from the right carrier frame. Disconnect the power switch from the power supply. Remove the two screws {B} from the lower right front side of the paper tray frame. 5. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5.

4085-001 4-10 Service Manual .

Repair Information 4-11 . Refer to “Left Cover Removal” on page 4-7. 4. 2. Remove the exit tray cover. Remove the left cover. Remove the three screws {A} that secure the left tray cover. Refer to “Rear Cover Removal” on page 4-3. Remove the rear cover. Refer to “Exit Tray Removal” on page 4-5. Remove the left tray cover.4085-001 Left Tray Cover Removal 1. 3. 5.

Refer to “Rear Cover Removal” on page 4-3. Refer to “Right Cover/Power Switch Removal” on page 4-9. Remove the right tray cover. Remove the three screws {A} that secure the right tray cover.4085-001 Right Tray Cover Removal 1. 4. 5. 4-12 Service Manual . 2. Refer to “Exit Tray Removal” on page 4-5. Remove the right cover. Remove the exit tray cover. 3. Remove the rear cover.

3. 2. Remove the rear cover. Disconnect the ink level and temperature sensor connector (J12) on the engine board. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. 6. 4. Remove the screw {A} from the sensor bracket. Refer to “Rear Cover Removal” on page 4-3.4085-001 Ink Levels and Temperature Sensor with Bracket Removal 1. Remove the operator panel cover. Repair Information 4-13 . Remove the sensor and bracket {B}. 5. Note the wire routing. Remove the right cover.

3. Refer to “Left Frame Cover Removal” on page 4-6. Remove left frame cover. 5. Note the routing of the ground cable. Remove the rear cover. 2. 4. 4-14 Service Manual . Remove the four screws and remove the engine board. Disconnect all connectors and cables from the engine board.4085-001 Engine Board /Cover Removal 1. Remove the two screws {A} from the engine board cover and the cover.

Be careful not to touch the encoder strip in any areas that the sensor uses. Remove all ink cartridges from carrier. 4. Disconnect the spring {C} and remove two screws {D} from the support shaft bracket located on the right side. 5. The open end of the keepers should face the rear of the carrier. Remove the encoder strip. Remove the carrier. Note the routing of the encoder strip through a sensor at the rear of the carrier. Loosen the set screw {A} on the belt tensioner. Remove all covers. Slide the carrier guide rod out the right side. 2. insure correct orientation of the support shaft bracket and linkage. 10. Remove the tension from the belt and retighten the set screw. Handle the encoder strip no further in than 4 cm from each side. Remove engine board cover. 6. Disconnect the carrier clip and cables from the engine board. Refer to “Tray 2 Covers Removal” on page 4-49. 3. 12.4085-001 Carrier with Card Removal 1. Note: When reinstalling. 8. 9. Repair Information 4-15 . Remove the belt. Remove the belt keepers from the ends of the belt {B}. 11. 7.

4085-001 4-16 Service Manual .

4085-001 Carrier 1st Stage Drive Belt Removal 1. 3. Remove print cartridges from the carrier. 5. Retighten in a clockwise order. Repair Information 4-17 . Open the front cover. Ensure that the belt is aligned by rotating the compound pulley two or three times. 6. Remove the two screws. 2. Remove one screw {A} from the right side of the rear cover. Loosen the three screws securing the motor plate to the motor assembly. as installed in the machine. Retighten the three screws to fix this position. 4. 5. Remove the three screws {B} from the gear bracket. Loosen the three screws to allow the motor bracket to apply proper belt tension. Remove the gear bracket. Remove the left and right end covers. Gently depress the motor so that the 1st stage drive belt is loosened. Remove multi-purpose feeder from the printer. 6. 10. Disconnect the pogo housing link on the right side. Remove the motor. 5. Depress the clips and remove the sensor. 4. Remove the original belt and install the new belt. Next tighten the screw closest to the tensioner spring. 2. Turn the printer off. Remove the clips and washer from both sides. 4. Remove the carrier printhead latch. 7. starting with the screw closest to the tensioner rivet. 7. Carrier Printhead Latch Removal 1. 8. 3. Remove the motor bracket from the printer frame. 9. 2. 3. Remove the rear cover. Multi-Purpose Feeder (MPF) Motor and Sensor Removal 1. Move the carrier to the center. Depress the clips on the electrical connector and remove the connector from gear bracket. 6.

4085-001 4-18 Service Manual .

4085-001 Power Supply Removal 1. and ground straps. 3. Remove the three mounting screws {A} that attach the power supply to the frame. 4. Repair Information 4-19 . 2. Disconnect all power supply cables. Refer to “Rear Cover Removal” on page 4-3. Note routing of the cables and straps. Remove the rear cover. Remove the power supply.

Remove three screws {A} from the transport carrier motor bracket. Slide the ink waste tank out the rear of the printer. then retighten the screw. 3. 5. 4. Slide the assembly out the rear of the printer and remove. Loosen the screw on the maintenance bracket and depress the spring. 8. Note the routing of the hose into tank. Refer to “Engine Board /Cover Removal” on page 4-14. Disconnect transport carrier motor cable from engine board. Refer to “Power Supply Removal” on page 4-19. 11.Push in the guide post {C} and move the pump housing maintenance station assembly forward and down to disconnect it from the shaft. 4-20 Service Manual . Remove the carrier belt. Remove the power supply. 6. Remove the motor and bracket. 9.Remove the screw {B} from the right side of the frame that secures the pump housing maintenance station assembly. 2.4085-001 Pump Housing/Maintenance Station/Ink Waste Tank/ Transport Carrier Motor Removal 1. 7. Remove all covers. Remove the spring from the rear of the maintenance station. 10. 12.

4085-001 Repair Information 4-21 .

Remove the left cover. Remove the index card. 6. See “Encoder Disk Feed Roller Assembly Removal” on page 4-34. 4. Remove the rear cover. 2. 3. 4-22 Service Manual . Remove the exit tray cover. 5. Refer to “Exit Tray Removal” on page 4-5.4085-001 Index Card Assembly Removal 1. Refer to “Rear Cover Removal” on page 4-3. Unplug the index board connector. Note: The index card and the encoder disk feed roller must be replaced as a matching set. Remove the three screws {A} from the index board. Refer to “Left Cover Removal” on page 4-7.

4085-001 Cover-Open Sensor Removal 1. Depress two latches and remove the cover-open sensor. Refer to “Left Cover Removal” on page 4-7. Refer to “Rear Cover Removal” on page 4-3. Unplug the cover-open sensor (J18) connector. Remove the engine card cover. Remove the exit tray cover. 2. 3. Repair Information 4-23 . 5. 6. Remove the left cover. Remove the rear cover. Refer to “Exit Tray Removal” on page 4-5. 4.

3. Remove the shield assembly. Refer to “Power Supply Removal” on page 4-19. Refer to “Coarse Alignment” on page 3-5. Refer to “Rear Cover Removal” on page 4-3. Disconnect (J14) RIP cable from the engine board. Note: Anytime the RIP card is replaced. 4-24 Service Manual . Remove the RIP card. Remove the rear cover.4085-001 RIP-EMC Shield Assembly/RIP Card Removal 1. Note routing of cable. 4. 2. Remove the six screws {A} from the RIP card. 5. a course alignment has to be done. Remove the six screws {B} from the shield assembly. 7. Remove the power supply. 6.

4085-001 Repair Information 4-25 .

Refer to “Power Supply Removal” on page 4-19. 6. Remove the PerfectFinish tank. 2. 5. Refer to “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24. 3. Disconnect the wire from paper path sensor. 12. Refer to “Rear Cover Removal” on page 4-3. 9. Disconnect the wire from the PerfectFinish sensor. unlatch the paper path sensor. Remove two screws and remove the PerfectFinish cartridge.4085-001 PerfectFinish Sensor Assembly/Rear Paper Path Sensor Removal 1. Remove the paper path sensor. 4-26 Service Manual . Lift the left side. Remove the RIP-EMC shield assembly and RIP card. Remove the power supply. 8. 10. Unsnap the rear paper path sensor arm and remove. 7. 4. Note the position of the spring. Remove the rear cover. Remove the PerfectFinish sensor. 11. Remove two screws from the PerfectFinish sensor.

4085-001 Frame From Base Removal 1. 3. 7. 2. 11. Remove the power supply. Place the printer on its back and remove five screws {D} from the base. 4. Refer to “Power Supply Removal” on page 4-19. 9. Remove the two screws {C} on the right side frame plate. 10. 6. Disconnect (J17) the paper port II from the engine board. 8. Refer to “Rear Cover Removal” on page 4-3. Lift and slide the frame forward and remove. Disconnect (J2) the transport carrier motor from the engine board. remove the PerfectFinish applicator to prevent spilling. Remove the maintenance tank through the rear of the printer. Remove the four screws {B} from the left side frame plate. Remove all covers. Before placing the printer on its back. Repair Information 4-27 . Disconnect the star wheel follower spring {A} from the base assembly. 5.

4085-001 4-28 Service Manual .

Disconnect the cam engine motor connector (J8) from the engine board. Note the routing of the wires. Remove the rear cover. Refer to “Left Cover Removal” on page 4-7. 4. Repair Information 4-29 . Remove the left cover. Remove the motor through the front of the printer.4085-001 Cam Engine Motor with Gear Removal 1. 2. Refer to “Exit Tray Removal” on page 4-5. Remove the exit tray cover. Refer to “Rear Cover Removal” on page 4-3. 5. 3. Remove the two screws {A} from the motor. 6.

4085-001 4-30 Service Manual .

Remove power supply.4085-001 Paper Feed Pick Arm Assembly with Motor and Paper Path Sensor Removal 1. 5. Remove the E-clip {A} from the pick assembly shaft. Refer to “Power Supply Removal” on page 4-19. 3. Remove the two lower screws on the base of the RIP shield. Disconnect the integrated tray connector (J6) from the engine board and disconnect the paper path sensor. Remove all covers. Slide the shaft to the left and remove the pick arm assembly. When reinstalling. Repair Information 4-31 . Remove the screw {B} from the paper feed frame assembly. Disconnect the wire from the paper path sensor and snap the sensor out to remove. Remove the frame from the base. note the routing of the wires and position of spring. Refer to “Frame From Base Removal” on page 4-27. 2. 4. 9. 7. 6. 8.

4-32 Service Manual . Refer to “Rear Cover Removal” on page 4-3. Remove the rear cover. Remove E-clips {A} from bellcrank diverter link and remove link. Remove helical drive gear {B} and cartridge drive gear under it. 3. 4. Remove three screws and remove plate.4085-001 PerfectFinish Gear Plate Removal 1. 2. Note the position of the cartridge drive gear under the helical drive gear.

Disconnect (J16) from the engine board. 5. Repair Information 4-33 . Remove engine board cover.4085-001 PerfectFinish Motor Removal 1. Remove rear cover. Note routing of wiring. Refer to “Tray 2 Covers Removal” on page 4-49. 6. Remove the two screws {A} from the motor. 2. Remove the two screws from the index motor. Refer to “Encoder Disk Feed Roller Assembly Removal” on page 4-34. Remove the rear cover. 3. Disconnect the PerfectFinish motor and encoder connector (J5) from the engine board. Remove the encoder disk feed roller assembly. Note the routing of the wiring. Index Motor Assembly Removal 1. 4. 2. Refer to “Rear Cover Removal” on page 4-3. Remove the motor. 4. Refer to “Rear Cover Removal” on page 4-3. Remove the motor. 3.

Remove the encoder disk feed roller assembly through the left side of the printer. 2. 4-34 Service Manual . 6. Refer to “Left Cover Removal” on page 4-7. 5. 7. See “Index Card Assembly Removal” on page 4-22. 8.4085-001 Encoder Disk Feed Roller Assembly Removal 1. Note orientation of springs before removing. 3. Remove the left cover. Remove the operator panel cover. Also replace the thrust bracket and the cleaning roller. Remove the exit tray cover. Refer to “Rear Cover Removal” on page 4-3. Remove the index board assembly. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. Remove the five backup roller springs {B}. Note: The index card and the encoder disk feed roller must be replaced as a matching set. Refer to “Exit Tray Removal” on page 4-5. Remove the thrust bracket CBM {A}. Remove the rear cover. 4.

4085-001 Repair Information 4-35 .

Remove the star wheel assembly. tank. Refer to “Engine Board /Cover Removal” on page 4-14. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 2. Remove the carrier and belt. 6. and transport carrier motor. 3. Disconnect the spring {A} connecting the base assembly to the star wheel cam follow assembly. Remove pump housing maintenance station. Remove the E-clip {B} from the right end of the star wheel shaft. 7. Disconnect the star wheel cam follow from the cam shaft assembly. 4-36 Service Manual .4085-001 Star Wheel Shaft Assembly Removal 1. Slide the shaft to the left and lift out. Remove all covers. 4. 5.

4085-001 Repair Information 4-37 .

2. 3. Press down gently on both sides and remove the paper feed platen out through the front of the printer. Be careful not to damage the platen bias studs. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4-38 Service Manual . Remove the star wheel shaft. Remove all covers. Remove the paper feed platen. 5.4085-001 Paper Feed Platen Assembly Removal 1. Refer to “Engine Board /Cover Removal” on page 4-14. Remove the pump housing maintenance station. tank. and the transport carrier motor. 6. 4. Remove the carrier and belt.

Remove the E-clip from the right end of the exit shaft. Repair Information 4-39 . 6. 4. lift and pull to the right to remove the exit shaft gear {A}. Refer to “Engine Board /Cover Removal” on page 4-14. and transport carrier motor. 8. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 5. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. Remove the exit shaft. Remove paper feed platen. 7. tank. Remove pump housing. 3. 2. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. Remove carrier and belt. Note the orientation of the gear before removal. Remove star wheel shaft. Remove all covers. Move exit shaft to the left.4085-001 Exit Shaft with Gear Removal 1. maintenance station.

12. See “Star Wheel Shaft Assembly Removal” on page 4-36. 10. Remove the carrier and belt. Pull the cam shaft assembly to the right and remove the gear. 11. 5. tank and transport carrier motor. Refer to “Engine Board /Cover Removal” on page 4-14. Remove paper feed platen. Remove the cam shaft assembly. note the position of the bat wings on the cam shaft. Remove the two E-clips {A} on the backup roller assembly shaft. 3. Refer to “Frame From Base Removal” on page 4-27. 4. Remove frame from base. Before removing the paper feed frame and motor. 4-40 Service Manual . Remove the two upper frame support screws {B}. 6. 9. Remove the star wheel shaft. Remove all covers. 2. Remove encoder disk and feed roller assembly. maintenance station. Disconnect all cable connectors from the engine board.4085-001 Paper Feed Frame and Motor/Cam Shaft Assembly Removal 1. 13. Remove pump housing. 8. Move the paper feed frame with motor to the right and remove. 7. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. Refer to “Encoder Disk Feed Roller Assembly Removal” on page 4-34.

4085-001 Repair Information 4-41 .

4085-001 4-42 Service Manual .

Remove the pump housing. Remove paper feed platen. 10. and transport carrier motor. Remove the frame from the base. Remove the three screws {B} from the left index frame pivot assembly. Remove the two index frame springs {A}. 11.4085-001 Left Index Frame Pivot Assembly Removal 1. Refer to “Frame From Base Removal” on page 4-27. 13. Refer to “Engine Board /Cover Removal” on page 4-14. 5. 12. Repair Information 4-43 . Refer to “Index Motor Assembly Removal” on page 4-33. Remove paper feed frame and motor. Remove encoder disk feed roller assembly. Remove the carrier and belt. Remove the star wheel shaft. maintenance station. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. 8. 9. tank. 6. 3. 4. Remove all covers. Remove the left index frame pivot assembly. Remove the index motor. Refer to “Paper Feed Frame and Motor/Cam Shaft Assembly Removal” on page 4-40. 2. 7. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. See “Encoder Disk Feed Roller Assembly Removal” on page 4-34. Disconnect all cable connectors from the engine board.

4085-001 4-44 Service Manual .

9. Repair Information 4-45 . Refer to “Encoder Disk Feed Roller Assembly Removal” on page 4-34. 7. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. Remove the carrier and belt. 6. tank and the transport carrier motor. Remove three screws and washers {B} from the right index frame pivot assembly. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. 5. Remove encoder disk feed roller assembly. Remove the right index frame pivot assembly. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove the star wheel shaft. 8. maintenance station. 4. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. Remove the paper feed platen. Remove the two index frame springs {A}.4085-001 Right Index Frame Pivot Assembly Removal 1. Remove the pump housing. Remove all covers. 2.

Remove bushings. Remove the rear cover. Pull forward and remove. 4-46 Service Manual . Remove the two E-clips from the ends of the bat wing shaft. Remove the spring between the cam followers. 4.4085-001 Bat Wings and Bushings Removal 1. 5. 2. 3. Refer to “Rear Cover Removal” on page 4-3.

Refer to “Paper Feed Frame and Motor/Cam Shaft Assembly Removal” on page 4-40. 4. Refer to “Encoder Disk Feed Roller Assembly Removal” on page 4-34. 3. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. Note: When removing the backup roller assembly. Refer to “Frame From Base Removal” on page 4-27. 10. Repair Information 4-47 . 2. two E-clips on the right side of the backup roller assembly.4085-001 Backup Roller Assembly Removal 1. Remove the index board assembly. 12. Move the backup roller assembly shaft to the left and remove it from the right bushing. 11. 5. 13. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. Disconnect all cable connectors from the engine board. Remove. Remove the backup roller springs. 14. Remove the encoder disk feed roller assembly. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 6. Remove all covers. Move the backup roller assembly to the right and out of the inner deflector and remove. from the left side frame. 9. Refer to “Index Card Assembly Removal” on page 4-22. tank and transport carrier motor. Remove star wheel shaft. Refer to “Engine Board /Cover Removal” on page 4-14. maintenance station. Remove carrier and belt. 7. 8. Remove the frame from the base. use care not to damage the paper sensor flag. Remove pump housing. Move the paper feed frame and motor to the right and remove. Remove the paper feed platen.

Lift the front door on the printer. disconnect carrier cables from the rear of the carrier and remove. Depress the retainer cable clip. Remove the carrier guide shaft from the carrier. 2. 3. 2. 5. Disconnect carrier cables from the engine board. Press the coil on the backup roller spring to center and remove. Note the position of the spring before removing. Remove all covers. Remove the engine board cover. Carrier/Cable Retainer Removal 1. 4.4085-001 Backup Roller Spring Removal 1. 4-48 Service Manual . move the cable to the right and remove. Unlatch the cable restraint. 6.

5. Note: When reinstalling the pump. Remove the operator panel cover. be sure the gear alignment is correct. Refer to “Rear Cover Removal” on page 4-3. Remove the exit tray. 3. 4. Remove ten screws {A} from Tray 2 covers. Remove the two screws from the peristaltic pump and disconnect the pump from the gear. Refer to “Exit Tray Removal” on page 4-5.4085-001 Peristaltic Pump Removal 1. 6. Refer to “Right Cover/Power Switch Removal” on page 4-9. 2. Tray 2 Covers Removal 1. Remove the power supply and tank. Remove the rear cover. 2. Remove the covers. Remove right cover. Repair Information 4-49 . Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5.

4085-001 Tray 2 Paper Pick Arm Assembly Removal 1. 5. 4-50 Service Manual . Remove E-clip {B} from pick assembly shaft. Remove the screw {C} from the paper feed frame assembly. 4. Remove all covers Remove eight screws {A} from Tray 2 base. 3. 2. Slide the shaft to the left and remove the pick arm assembly.

4085-001 Repair Information 4-51 .

4.4085-001 Tray 2 Paper Feed Motor and Card Assembly Removal 1. Remove the four screws from the paper port connector frame. Remove the paper port connector frame. 6. 5. Remove the motor. 2. 4-52 Service Manual . Remove the left cover from Tray 2. Disconnect the paper feed motor connector. Remove the two paper feed motor screws {A}. 3.

4085-001 5. Connector Locations Engine Board J1 J2 J3 Power Supply Carrier Motor Maintenance Station Motor and Homing Operator Panel Thin-Coat Motor and Encoder Integrated Tray Cam System Thin-Coat Sensing MPF-Feeder Paper-Path Sensing Ink-Level and Temperature Sensing RIP Index System Index Motor Paper Port II Tray2 Cover-Open Sensor Carrier Connector Carrier Connector Carrier Connector J4 J5 J6 J8 J9 J10 J11 J12 J14 J15 J16 J17 J18 J21 J22 J23 Connector Locations 5-1 .

4085-001 RIP Card 5-2 Service Manual .

) J1 J2 J3 J4 Power Supply Engine Parallel USB Connector Locations 5-3 .4085-001 RIP Card (cont.

4085-001 Optional Tray 2 J1 J2 J3 J4 Paper Feed Motor Passthru Sensor Paper Feed Pic Motor Paperport II and Power 5-4 Service Manual .

use 0.003 grams per pulley. ensure that no grease contacts the encoder strip as a carrier system stall could result during the Power-OnSequence or during printing. Preventive Maintenance 6-1 . use approximately 0. Lubrication Specifications Lubricate only when parts are replaced or as needed. Follow these recommendations to prevent problems and maintain optimum performance. Note: Do not let the Nyogel 744 come in contact with the pogo pin housing. Use 0.4085-001 6. Carrier Transport System Pulleys • Apply Shell Tellus #100 to the pulley bores of the top idler pulleys {3} and tensioner {13}. IBM no. Use of lubricants other than those specified can cause premature failure. but should not drip. For reference.06 grams for the 8mm shaft {1}. Some unauthorized lubricants may chemically attack polycarbonate parts. PN 1280443 (Approved equivalents: Mobil DTE27. For reference. When applying Nyogel 744 to the top of the 8mm shaft. Carrier Shafts • Apply Nye Nyogel 744 uniformly across the top portion of the 8mm {1} and 12mm carrier shafts.16 grams for the 12 mm shaft. 23 grease (Approved equivalent Shell Darina 1). Fuchs Renolin MR30).03 to 0. but not dripping from the shafts. Numbers in {} refer to items in Assembly 4: Carrier Transport. not on a scheduled basis. and grease. Preventive Maintenance This chapter contains lubrication specifications. Shell Tellus 100. • Remove any excessive coatings or accumulations with a lintfree cloth. The grease should be visible to the eye on the shafts. Use IBM no. The amount of oil to b used should be visible in the pulley bore.08 to 0. May cause machine failure. 10 oil. PN 99A0394 Nyogel 744 to lubricate appropriate areas of the machine.

being careful to avoid contamination of the carrier card or carrier cables. Use of an appropriate fixture is needed to properly lubricate the ink tank pogo pins. For reference. Depress the applicator bottle on each set of pogo pins only once. use approximately 0. The amount of Shell Tellus #100 to be used should be visible on the stud but not dripping or running onto the motor bracket.05 grams wet. If appropriate. Carrier Latch Camshaft Lubrication • With the carrier handle raised to disengage the camshaft. remove any excess lubricant from the bracket around these regions. Lubricant should not drip down the carrier card bracket.02 grams per cam) to the carrier backup bracket in the regions directly behind the camshaft lobes. Open and close the handle a couple of times to ensure that the contacting surfaces of the cams and bracket have been lubricated.003 grams on the idler pulley stud.005 grams on the compound pulley stud and approximately 0. For reference. • 6-2 Service Manual . Shake well before applying Nyetact 570H-10 lubricant. Motor Pulley Studs • Apply Shell Tellus #100 oil to the idler stud and compound pulley stud {8}. this amount should be about 0. pulleys or frame. • • Carrier Card Pogo Pins • Use Nye Tact 570H-10 to lubricate the ink tank pogo pins on the carrier card assembly.4085-001 • Avoid oil contact with the outer pulley surface and flanges that contact the belt. apply small drops of Nye Uniflor 8512 (0. avoiding excessive drippage on other parts of the carrier card.01 grams to 0.

PP: in the Description column indicates the part is available in the listed parts packet. Parts Catalog How To Use The Parts Catalog • NS: (Not Shown) in the Asm-Index column indicates that the • part is procurable but is not shown in the illustration. Parts Catalog 7-1 .4085-001 7.

4085-001 Assembly 1: Covers 7-2 Service Manual .

Rear Cover. (PP) Parts Catalog 7-3 .4085-001 Assembly 1: Covers AsmIndex 1-1 2 3 4 5 6 7 8 9 10 11 12 NS Part Number 12G6073 12G6070 12G6069 12G6065 12G6061 12G6063 12G6072 12G6075 12G6062 12G6060 12G6071 12G6064 12G6076 Units 1 1 1 1 1 1 1 1 1 1 1 1 Description Cover Assembly. Right Cover. Left Top Door Assembly Cover. Left Tray Cover. Right Tray Cover Assembly. Manual Feed Door. Left Frame Screws. Rear Cover. Operator Panel Cover. Exit Tray Paper Tray Assembly Cover.

4085-001

Assembly 2: Paper Feed

7-4 Service Manual

4085-001

Assembly 2: Paper Feed

AsmIndex 2-1 2 3

Part Number 12G6024 12G6000 12G6092

Units 1 1 2

Description Paper Out Sensor Paper Feed Pick Assembly with Motor Pick Tires

Parts Catalog 7-5

4085-001

Assembly 2 (cont.): Paper Feed

7-6 Service Manual

4085-001

Assembly 2 (cont.): Paper Feed

AsmIndex 2-2 3 4

Part Number 12G6003 12G6004 12G6005

Units 1 1 1

Description Left Bat Wing with Bushings Right Bat Wing with Bushings Bat Wing Follower Assembly

Parts Catalog 7-7

4085-001

Assembly 2 (cont.): Paper Feed

7-8 Service Manual

Cartridge Assembly Sensor Assembly with Cable . Automatic Sheet Feed PerfectFinish Drive Plate Assembly Roller.Fluid Level Screws. PerfectFinish Platen with Spring and Levers Assembly Shaft. Cleaning Applicator. Index Assembly Starwheel Follower with Spring Assembly Plate. Second Path Paper Exit Backup Roll Assembly Motor Assembly. Camshaft Static Brush Bracket Assembly Motor.): Paper Feed AsmIndex 2-5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NS NS NS NS NS NS NS Part Number 12G6010 12G6031 12G6008 12G6028 12G6027 12G6029 12G6006 12G6026 12G6013 12G6074 12G6025 12G6032 12G6014 12G6007 12G6009 12G6094 12G6095 12G6250 12G6076 12G6097 12G6098 12G6099 1 1 1 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Deflector Assembly. Left Pivot Left Plate Assembly. (PP) Retainer/Bearing/Bushing (PP) Spring (PP) Washer/Clip/Keeper/Tubing (PP) Parts Catalog 7-9 .4085-001 Assembly 2 (cont. Right Pivot Cam Shaft Assembly with Spring Motor. Exit Assembly with Gears Star Wheel Shaft Assembly Plate.

4085-001

Assembly 3: Electronics

7-10 Service Manual

4085-001

Assembly 3: Electronics
AsmIndex 3-1 2 3 4 5 6 7 8 9 10 11 12 Part Number 12G6059 12G6058 12G6067 12G6066 12G6057 12G6048 12G6055 12G6044 12G6018 12G6053 12G6093 1339535 Units 1 1 1 1 1 1 1 1 1 1 1 1 Description RIP Card Shield, RIP Enclosure Cable, Operator Panel Operator Panel Assembly Power Supply Engine Board Sensor, Ink Level Index Card/Feedroll Encoder Disc Assembly Top Door Switch with Retainer Cable, Engine to RIP Bracket, Thrust Power Cord, Canada, United States, Bolivia, Caribbean, Columbia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Peru, Puerto Rico, Venezuela, Virgin Islands, Papua, New Guinea, Phillippines, South Korea, Taiwan, Thailand Power Cord, Italy Power Cord, Brazil, Paraguay, Uruguay Power Cord, Chile Power Cord, Abu Dhabi, Ajman, Bahrain, Dubai, Fujeirah, Iraq, Kuwait, Lybia, Oman, Pakistan, Qatar, Ras-AlKhaimah, Sharjah, U.A.E., UK/Ireland/ Iceland, Umm-Al-Qwain, Yemen, Hong Kong, Malasia, Singapore Power Cord, Australia, New Zealand Power Cord, Israel Power Cord, Switzerland (Fr), Switzerland (German) Switzerland (It) Power Cord, Botswana, Lesotho, Namibia, South Africa, Bangladesh, Sri Lanka

12 12 12 12

1339542 1342530 1342534 1339537

1 1 1 1

12 12 12 12

1339536 1339539 1339540 1339541

1 1 1 1

Parts Catalog 7-11

4085-001

Assembly 3 (cont.): Electronics

7-12 Service Manual

4085-001

Assembly 3 (cont.): Electronics
AsmIndex 12 12 Part Number 1339545 1339538 Units 1 1 Description Power Cord, Argentina Power Cord, Albania, Algeria, Armenia, Austria, Azerbijan, Belarus, Belgium, Benin, Bosnia, Bulgaria, Burkina-Faso, Cameroon, Central African Republic, Chad, Chechenya, Comoros, Congo, Croatia, Czek Republic, Djbouti, Egypt, Equatorial Guinea, Estonia, Euro English, Finland, France, French Guyana, Gabon, Gambia, Georgia, Germany, Greece, Guadeloupe, Guinea, Hungary, Iran, Ivory Coast, Jordan, Kazakhstan, Kirghizistan, Kyrgyz Republic, La Reunion, Latvia, Lebanon, Lettonia, Lithuania, Macedonia, Madagascar, Mali, Martinique, Mauritania, Mauritius, Mayottes, Moldavia, Moldova, Morocco, Netherlands, New Caledonia, Niger, Norway, Poland, Portugal, Romania, Russia, Saint Pierre et Miqueion, Senegal, Seychelles, Slovakia, Slovenia, Spain/Catalan, Sweden, Syria, Tahiti, Tajikistan, Togo, Tunisia, Turkey, Turkmenistan, Ukraine, Uzbekistan, Vanuatu, Wallis & Futuna, Yugoslavia (Serbia & Montenegro) Power Cord, Saudia Arabia, Indonesia, Japan Power Cord, Peoples Republic China Cables, Camshaft Motor and TDC Sensor PerfectFinish Sensor (Flag) Power Switch with Cable Input Sensor PerfectFinish Sensor Cable Cable, Auto Connect - Tray 2 Cable, Rear Feeder Cable, Index Sensor Cable, Fluid Level Sensor Cover, Engine Board Assembly Screws, (PP)

12 12 NS NS NS NS NS NS NS NS NS NS NS

1342514 43H9547 12G6012 12G6017 12G6045 12G6046 12G6047 12G6050 12G6051 12G6052 12G6054 12G6068 12G6076

1 1 1 1 1 1 1 1 1 1 1 1 1

Parts Catalog 7-13

4085-001

Assembly 3 (cont.): Electronics

7-14 Service Manual

4085-001 Assembly 3 (cont.): Electronics AsmIndex NS NS NS Part Number 12G6097 12G6098 12G6099 Units 1 1 1 Description Retainer/Bearing/Bushing (PP) Spring (PP) Washer/Clip/Keeper/Tubing (PP) Parts Catalog 7-15 .

4085-001 Assembly 4: Carrier Transport 7-16 Service Manual .

Nyogel 744 Grease Packet. Encoder Strip Encoder. Carrier Drive Belt Link. Pogo Housing Screws. Carrier Drive Carrier Cables with Retainer and Clamps Belt. Carrier Gears. Carrier Drive Assembly with Belt Carrier Assembly with Cables and Clamps Printhead Latch. Carrier Drive with Keepers Pulley Assembly with Shaft-Top Idler Clip. Upper Carrier with Brackets Belt. Compound/Carrier Lift Carrier Lift Assembly Tensioner. Carrier Drive Motor.4085-001 Assembly 4: Carrier Transport AsmIndex 4-1 2 3 4 5 6 7 8 9 10 11 12 13 14 NS NS NS NS Part Number 12G6033 12G6037 12G6038 12G6040 12G6039 12G6035 12G6016 12G6015 12G6034 12G6036 12G6042 12G6041 12G6030 12G6200 12G6076 99A0394 99A0462 12G6097 1 1 1 Units 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Description Shaft. (PP) Grease Packet. IBM 23 Retainer/Bearing (PP) Parts Catalog 7-17 .

4085-001 Assembly 5: Maintenance Station 7-18 Service Manual .

4085-001 Assembly 5: Maintenance Station AsmIndex 5-1 2 3 4 5 6 7 8 NS NS Part Number 12G6056 12G6022 12G6019 12G6021 12G6020 12G6091 12G6024 12G6099 12G6023 12G6076 Units 1 1 1 1 1 2 1 1 1 Description Waste Ink Bottle with Belt Shield Maintenance Regulator Assembly Maintenance Motor Assembly with Gear Peristaltic Pump Assembly Maintenance Station Assembly Wipers. (PP) Parts Catalog 7-19 . Maintenance Maintenance Homing Sensor Washer/Clip/Keeper/Tubing (PP) Maintenance Cable Screws.

4085-001 Assembly 6: Optional Tray 2 7-20 Service Manual .

Redrive with Gear Assembly Cover.4085-001 Assembly 6: Optional Tray 2 AsmIndex 6-1 2 3 4 5 6 7 8 9 10 NS NS NS NS Part Number 12G6088 12G6002 12G6049 12G6046 12G6086 12G6085 12G6089 12G6001 12G6083 12G6087 12G6078 12G6080 12G6076 12G6098 Units 1 4 1 1 1 1 1 1 1 1 1 1 1 1 Description Cover. Rear (OP Tray 2) Wear Strips Paper Feed Pick Assembly with Motor . Tray 2 Passthru Cover.250 Option Final Assembly Sensor.Paper Tray 2 with Spring Motor. Front (OP Tray 2) Card. Secondary Tray Detent . Left Side (OP Tray 2) Cable. Tray 2 Power and Paper Port Cable. Right Side (OP Tray 2) Cover. Tray 2 Stepper Motor Screw (PP) Spring (PP) Parts Catalog 7-21 .

4085-001 Assembly 7: Optional Multi-Purpose Feeder 7-22 Service Manual .

4085-001 Assembly 7: Optional Multi-Purpose Feeder AsmIndex 7-1 2 3 Part Number 12G6077 12G6011 12G6084 Units 1 1 1 Description Guide. MPF Rear Paper Feeder. Auxillary Sheet MFP Motor with wire Parts Catalog 7-23 .

4085-001 Assembly 8: Optional MarkNet External Print Server 7-24 Service Manual .

4085-001 Assembly 8: Optional MarkNet External Print Server AsmIndex 8-1 NS Part Number 12G6090 12G6251 Units 1 1 Description MarkNet™ External Print Server MarkNet XP Cable Parts Catalog 7-25 .

4085-001 7-26 Service Manual .

1-7 Operator Panel Menu Definition 3-44 Other Resets 3-17 P Plastic Latches 4-2 POST Sequence 2-49 Symptom Table 2-50 Index X-1 . 7-6.4085-001 Index A Abbreviations 1-3 Adjustments 4-2 Aids Diagnostic 3-1 Printer Operations 3-1 Aligning Printheads 3-5 Assemblies 1 Covers 7-2 2 Paper Feed 7-4. 3-38 Hardware Tests 3-22 Input Tray Tests 3-27 Printer Setup 3-35 Subsystem Tests 3-31 O Operator Panel Buttons 1-5 Menus 1-4. 7-8 3 Electronics 7-10 4 Carrier Transport 7-16 5 Maintenance Station 7-18 6 Optional Tray 2 7-20 7 Optional Multi-Purpose Feeder 7-22 8 Optional MarkNet External Print Server 7-24 Attendance Messages 2-24 Supplies Tests 3-34 Diagnostics Menu Group (Mode 1 Printing) 3-62 Diagnostics Menu Group (Mode 2 Non-printing) 3-63 E Error Indicator Table 2-3 ESD-Sensitive Parts 4-1 Exiting Diagnostics Mode 3-39 H Hex Trace Debug Mode 3-19 I Internal Power Supply Specifications 1-2 J Jam Jog Function 2-2 Job Menu 3-46 B Busy/Waiting Menu Group 3-45 Button Test 3-23 L Linking Input Trays 3-8 Lubrication Specifications 6-1 C Canceling a Print Job 3-12 Changing Ink Cartridges 3-4 Changing Printheads 3-4 Cleaning Printheads 3-7 Configuration Menu Group 3-60 Contacts Page Fixed Settings 3-22 M Maintenance Approach 1-2 Manual Duplex 3-10 Menu Page Fixed Settings 3-11 Menus 3-39 D Diagnostic Aids 3-1 Diagnostic Information 2-1 Diagnostics (Mode 1) Print Tests 3-19 Diagnostics (Mode 2) Base Sensor Tests 3-29 Error Log 3-37.

4085-00X Power Consumption 1-1 Print Quality Test Page 3-8 Printer Indicator Light 1-4 Printer Messages 1-6 Printer Operations CE Diagnostics Mode 3-2 Clear NVRAM 3-3 Disable/Enable OP Menus 3-2 Flash Engine Code Mode 3-3 Power-On Reset Button Functions 3-1 Printer Settings 1-9 Printing Menu Settings Page 3-10 Problems Carrier Transport 2-51 Communications 2-51 Maintenance Station 2-51 Operator Panel 2-52 Paper Feed 2-52 Power 2-52 Print Quality 2-53 Left Index Frame Pivot 4-43 Left Tray Cover 4-11 Maintenance Station 4-20 Multi-Purpose Feeder Motor 4-17 Multi-Purpose Feeder Sensor 4-17 Operator Panel 4-5 Paper Feed Frame 4-40 Paper Feed Motor 4-40 Paper Feed Pick Assembly 4-31 Paper Feed Platen 4-38 PerfectFinish Gear Plate 4-32 PerfectFinish Motor 4-33 PerfectFinish Sensor 4-26 Peristaltic Pump 4-49 Power Supply 4-19 Pump Housing 4-20 Rear Cover 4-3 Rear Paper Path Sensor 4-26 Right Cover 4-9 Right Index Frame Pivot 4-45 Right Tray Cover 4-12 RIP Card 4-24 Star Wheel Shaft 4-36 Temperature Sensor 4-13 Transport Carrier Motor 4-20 Tray 2 Card Assembly 4-52 Tray 2 Covers 4-49 Tray 2 Paper Feed Motor 4-52 Tray 2 Paper Pick Arm Assembly 4-50 Repair Information 4-1 Resetting the Printer 3-14 Restoring Factory Defaults 3-12 R Ready Menu Group 3-48 Removals Backup Roller Assembly 4-47 Backup Roller Spring 4-48 Bat Wings 4-46 Cam Engine Motor 4-29 Cam Shaft 4-40 Carrier Cable and Retainer 4-48 Carrier Printhead Latch 4-17 Carrier with Card 4-15 Cover-Open Sensor 4-23 Encoder Disk Feed Roller Assembly 4-34 Engine Board 4-14 Exit Shaft with Gear 4-39 Exit Tray Cover 4-5 Frame From Base 4-27 Index Board 4-22 Index Motor 4-33 Ink Level Sensor 4-13 Ink WasteTank 4-20 Left Cover 4-7 S Safety Information viii Service Checks 2-54 Cam System Motor 2-70 Index Motor 2-57 Maintenance Functions 2-54 Maintenance Station 2-54 Multi-Purpose Feeder Motor 2-58 Multi-Purpose Feeder Sensor 2-58 X-2 Service Manual .

4085-001 Operator Panel (Buttons) 2-59 Operator Panel (LCD) Display 2-60 Options 2-60 Paper Feed 2-61 Power Supply 2-64 Print Quality 2-66 RIP Card 2-65 Transport 2-68 Service Messages 2-2 Start 2-1 Status Messages 2-14 Symptom Tables 2-51 W Warning Messages 2-13 Part Numbers 12G6000 12G6002 12G6003 12G6004 12G6005 12G6006 12G6007 12G6008 12G6009 12G6010 12G6011 12G6012 12G6013 12G6014 12G6015 12G6016 12G6017 12G6018 12G6019 12G6020 12G6021 12G6022 12G6023 12G6024 12G6025 12G6026 12G6027 12G6028 12G6029 12G6030 12G6031 12G6032 12G6033 12G6034 12G6035 12G6036 12G6037 12G6038 12G6039 12G6040 12G6041 12G6042 7-5 7-21 7-7 7-7 7-7 7-9 7-9 7-9 7-9 7-9 7-23 7-13 7-9 7-9 7-17 7-17 7-13 7-11 7-19 7-19 7-19 7-19 7-19 7-5. 7-19 7-9 7-9 7-9 7-9 7-9 7-17 7-9 7-9 7-17 7-17 7-17 7-17 7-17 7-17 7-17 7-17 7-17 7-17 T Tests Cap Printheads 3-31 Carrier System 3-32 DRAM Memory 3-23 Index System 3-33 Ink Level Sensor 3-31 Ink Tank Memories 3-34 K&C Thermal Sense Resistor 3-35 LCD Hardware 3-22 M&Y Thermal Sense Resistor 3-35 Maintenance Sled 3-33 Miscellaneous Sensors 3-30 MP Feeder Sensor 3-28 Paper Path Sensors 3-29 Parallel Wrap 3-25 Printhead Memories 3-34 ROM Memory 3-24 Supplies Sensors 3-29 Tray 1 Sensor 3-27 Tray 2 Sensor 3-27 Uncap Printheads 3-31 Tools 1-3 U Unsolicited Manual Feed 3-10 User Error Messages 2-70 User Status Messages 2-10 Index X-3 .

7-17 7-9. 7-23 7-21 7-21 7-21 7-21 7-23 7-21 7-21 7-21 7-21 7-21 7-25 7-19 7-11 12G6094 12G6095 12G6097 12G6098 12G6099 12G6200 12G6250 12G6251 1339535 1339536 1339537 1339538 1339539 1339540 1339541 1339542 1339545 1342514 1342530 1342534 43H9547 99A0394 99A0462 7-9 7-9 7-9. 7-13.4085-00X 12G6044 12G6045 12G6046 12G6047 12G6048 12G6049 12G6051 12G6052 12G6053 12G6054 12G6055 12G6056 12G6057 12G6058 12G6059 12G6060 12G6061 12G6062 12G6063 12G6064 12G6065 12G6066 12G6067 12G6068 12G6069 12G6070 12G6071 12G6072 12G6073 12G6074 12G6075 12G6076 7-21 12G6077 12G6078 12G6080 12G6081 12G6083 12G6084 12G6085 12G6086 12G6087 12G6088 12G6089 12G6090 12G6091 12G6093 7-11 7-13 7-13 7-13 7-11 7-21 7-13 7-13 7-11 7-13 7-11 7-19 7-11 7-11 7-11 7-3 7-3 7-3 7-3 7-3 7-3 7-11 7-11 7-13 7-3 7-3 7-3 7-3 7-3 7-9 7-3 7-3. 7-19 7-17 7-9 7-25 7-11 7-11 7-11 7-13 7-11 7-11 7-11 7-11 7-13 7-13 7-11 7-11 7-13 7-17 7-17 X-4 Service Manual . 7-19. 7-9. 7-17. 7-21 7-9.